US20240162671A1 - Reconfigurable welding-type power sockets and power plugs - Google Patents
Reconfigurable welding-type power sockets and power plugs Download PDFInfo
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- US20240162671A1 US20240162671A1 US18/418,701 US202418418701A US2024162671A1 US 20240162671 A1 US20240162671 A1 US 20240162671A1 US 202418418701 A US202418418701 A US 202418418701A US 2024162671 A1 US2024162671 A1 US 2024162671A1
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- keyed
- plug
- welding
- removable insert
- entryway
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R27/00—Coupling parts adapted for co-operation with two or more dissimilar counterparts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
- B23K9/1006—Power supply
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/20—Pins, blades, or sockets shaped, or provided with separate member, to retain co-operating parts together
- H01R13/207—Pins, blades, or sockets shaped, or provided with separate member, to retain co-operating parts together by screw-in connection
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/64—Means for preventing incorrect coupling
- H01R13/642—Means for preventing incorrect coupling by position or shape of contact members
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/64—Means for preventing incorrect coupling
- H01R13/645—Means for preventing incorrect coupling by exchangeable elements on case or base
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R31/00—Coupling parts supported only by co-operation with counterpart
- H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/56—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation one conductor screwing into another
Definitions
- the present disclosure generally relates to welding-type systems, and more particularly to welding-type power sockets and power plugs that are configurable (and/or reconfigurable).
- Some welding systems include welding components (e.g., torch, clamp, wire feeder, etc.) that are powered by a welding power supply. Power is transferred from a welding power supply to a welding component via a cable connection with a power socket of the power supply, such as through a plug end of the cable.
- a welding power supply e.g., torch, clamp, wire feeder, etc.
- Power is transferred from a welding power supply to a welding component via a cable connection with a power socket of the power supply, such as through a plug end of the cable.
- some power supplies have power sockets that are configured to connect only with one particular type of plug and/or cable. This may make it difficult to connect one type of plug to a power socket designed for a different type of plug.
- the present disclosure is directed to welding-type power sockets and plugs that are configurable (and/or reconfigurable), for example, substantially as illustrated by and/or described in connection with at least one of the figures, and as set forth more completely in the claims.
- FIG. 1 illustrates an example of a welding-type system, in accordance with aspects of this disclosure.
- FIG. 2 is a block diagram of the example welding-type system of FIG. 1 , in accordance with aspects of this disclosure.
- FIG. 3 a is a perspective exploded view of an example welding-type power socket, in accordance with aspects of this disclosure.
- FIG. 3 b is a front view of the example welding-type power socket of FIG. 3 a with one of the socket inserts of FIG. 3 a , in accordance with aspects of this disclosure.
- FIG. 3 c is a cross-section of the example welding type power socket of FIG. 3 b , along the line 3 c - 3 c in FIG. 3 b , in accordance with aspects of this disclosure
- FIG. 4 a is a front view of an example bulkhead, in accordance with aspects of this disclosure.
- FIG. 4 b is a cross-section of the example bulkhead of FIG. 4 a , along the line 4 b - 4 b of FIG. 4 a , in accordance with aspects of this disclosure.
- FIG. 5 a is a front view of an example socket connector, in accordance with aspects of this disclosure.
- FIG. 5 b is a cross-section of the example socket connector of FIG. 5 a , along the line 5 b - 5 b of FIG. 5 b , in accordance with aspects of this disclosure.
- FIG. 5 c is a front view of another example socket connector, in accordance with aspects of this disclosure.
- FIG. 5 d is a cross-section of the example socket connector of FIG. 5 d , along the line 5 d - 5 d in FIG. 5 c , in accordance with aspects of this disclosure.
- FIG. 6 a is a front view of an example insert, in accordance with aspects of this disclosure.
- FIG. 6 b is a cross-section of the example insert of FIG. 6 a , along the line 6 b - 6 b of FIG. 6 a , in accordance with aspects of this disclosure.
- FIG. 6 c is a front view of another example insert, in accordance with aspects of this disclosure.
- FIG. 6 d is a cross-section of the example insert of FIG. 6 c , along the line 6 d - 6 d of FIG. 6 c , in accordance with aspects of this disclosure.
- FIG. 6 e is a front view of another example insert, in accordance with aspects of this disclosure.
- FIG. 6 f is a cross-section of the example insert of FIG. 6 e , along the line 6 f - 6 f of FIG. 6 e , in accordance with aspects of this disclosure.
- FIG. 7 a is a perspective exploded view of an example plug assembly, in accordance with aspects of this disclosure.
- FIG. 7 b is a perspective exploded view of another example plug assembly, in accordance with aspects of this disclosure.
- FIG. 8 a is a perspective view of an example plug adapter, in accordance with aspects of this disclosure.
- FIG. 8 b is a front view of the example plug adapter of FIG. 8 a , in accordance with aspects of this disclosure.
- FIG. 8 c is a cross-section of the example plug adapter of FIG. 8 b , along the line 8 c - 8 c of FIG. 8 b , in accordance with aspects of this disclosure.
- FIG. 8 d is a perspective view of another example plug adapter, in accordance with aspects of this disclosure.
- FIG. 8 e is a front view of the example plug adapter of FIG. 8 d , in accordance with aspects of this disclosure.
- FIG. 8 f is a cross-section of the example plug adapter of FIG. 8 e , along the line 8 f - 8 f of FIG. 8 e , in accordance with aspects of this disclosure.
- FIG. 8 g is a perspective view of another example plug adapter, in accordance with aspects of this disclosure.
- FIG. 8 h is a front view of the example plug adapter of FIG. 8 g , in accordance with aspects of this disclosure.
- FIG. 8 i is a cross-section of the example plug adapter of FIG. 8 b , along the line 8 c - 8 c of FIG. 8 b , in accordance with aspects of this disclosure.
- FIG. 8 j is a perspective view of another example plug adapter, in accordance with aspects of this disclosure.
- FIG. 8 k is a front view of the example plug adapter of FIG. 8 j , in accordance with aspects of this disclosure.
- FIG. 8 l is a cross-section of the example plug adapter of FIG. 8 k , along the line 81 - 81 of FIG. 8 k , in accordance with aspects of this disclosure.
- FIG. 8 m is a perspective view of another example plug adapter, in accordance with aspects of this disclosure.
- FIG. 8 n is a front view of the example plug adapter of FIG. 8 m , in accordance with aspects of this disclosure.
- FIG. 8 o is a cross-section of the example plug adapter of FIG. 8 n , along the line 8 o - 8 o of FIG. 8 n , in accordance with aspects of this disclosure.
- FIG. 8 p is a perspective view of another example plug adapter, in accordance with aspects of this disclosure.
- FIG. 8 q is a front view of the example plug adapter of FIG. 8 p , in accordance with aspects of this disclosure.
- FIG. 8 r is a cross-section of the example plug adapter of FIG. 8 q , along the line 8 r - 8 r of FIG. 8 q , in accordance with aspects of this disclosure.
- FIG. 9 a is a front view of an example plug receptacle, in accordance with aspects of this disclosure.
- FIG. 9 b is a cross-section of the example plug receptacle of FIG. 9 a , along the line 9 b - 9 b of FIG. 9 a , in accordance with aspects of this disclosure.
- FIG. 10 a is a front view of the plug assembly of FIG. 7 a , with one of the plug adapters of FIG. 7 a , in accordance with aspects of this disclosure.
- FIG. 10 b is a cross-section of the plug assembly of FIG. 10 a , along the line 10 b - 10 b in FIG. 10 a , in accordance with aspects of this disclosure.
- FIG. 10 c is a cross section of the plug assembly of FIG. 7 b , with one of the plug adapters of FIG. 7 b , in accordance with aspects of this disclosure.
- FIG. 11 is a flow diagram illustrating an example method of operation, in accordance with aspects of this disclosure.
- reference numerals utilizing lettering refer to instances of the same reference numeral that does not have the lettering (e.g., socket connectors 500 ).
- the examples described herein are not limited to only the recited values, ranges of values, positions, orientations, and/or actions but rather should include reasonably workable deviations.
- “and/or” means any one or more of the items in the list joined by “and/or”.
- “x and/or y” means any element of the three-element set ⁇ (x), (y), (x, y) ⁇ . In other words, “x and/or y” means “one or both of x and y”.
- “x, y, and/or z” means any element of the seven-element set ⁇ (x), (y), (z), (x, y), (x, z), (y, z), (x, y, z) ⁇ . In other words, “x, y and/or z” means “one or more of x, y and z”.
- the term “attach” means to affix, couple, connect, join, fasten, link, and/or otherwise secure.
- the term “connect” means to attach, affix, couple, join, fasten, link, and/or otherwise secure.
- circuits and “circuitry” refer to physical electronic components (i.e., hardware) and any software and/or firmware (“code”) which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware.
- code software and/or firmware
- a particular processor and memory may comprise a first “circuit” when executing a first one or more lines of code and may comprise a second “circuit” when executing a second one or more lines of code.
- circuitry is “operable” and/or “configured” to perform a function whenever the circuitry comprises the necessary hardware and/or code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).
- a control circuit may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, DSPs, etc., software, hardware and/or firmware, located on one or more boards, that form part or all of a controller, and/or are used to control a welding process, and/or a device such as a power source or wire feeder.
- the term “memory” and/or “memory device” means computer hardware or circuitry to store information for use by a processor and/or other digital device.
- the memory and/or memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like.
- ROM read-only memory
- RAM random access memory
- CDROM compact disc read-only memory
- EPROM erasable programmable read-only memory
- EEPROM electrically-erasable programmable read-only memory
- processor means processing devices, apparatuses, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable.
- processor includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing.
- the processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC).
- DSP digital signal processing
- ASIC application-specific integrated circuit
- the processor may be coupled to, or integrated with a memory device.
- controlling “power” may involve controlling voltage, current, energy, and/or enthalpy, and/or controlling based on “power” may involve controlling based on voltage, current, energy, and/or enthalpy.
- welding-type power refers to power suitable for welding, cladding, brazing, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding), carbon arc cutting or gouging, and/or resistive preheating.
- a welding-type power supply and/or power source refers to any device capable of, when power is applied thereto, supplying welding, cladding, brazing, plasma cutting, induction heating, laser (including laser welding, laser hybrid, and laser cladding), carbon arc cutting or gouging and/or resistive preheating, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.
- a removable insert for a socket of a welding power supply comprising a base having a keyed entryway configured to connect with a key interface of a plug, a nose comprising a contact surface configured to make electrical contact with a complementary contact surface of a socket connector, and a coupler configured to couple the removable insert to the socket connector.
- the keyed entryway comprises a bore encircled by an inner surface of the base, the inner surface having a keyed surface.
- the keyed surface comprises a latch that protrudes into the bore or an axial groove that expands the bore.
- the contact surface comprises a frustoconical surface.
- the coupler comprises a shoulder screw having a head, a screw thread, and a shank connecting the head to the screw thread, the screw thread configured to engage complementary threaded grooves of the socket connector.
- the head of the shoulder screw is positioned within the nose, the head having a tool interface configured for coupling to a tool.
- the coupler further comprises a nut engaged to the screw thread.
- a welding power supply comprising a housing having an electrical panel with an insulating bulkhead, and a socket connector within the insulating bulkhead, the socket connector comprising a bore encircled by an inner surface, the inner surface comprising a contact surface configured to make electrical contact with a complementary contact surface of a removable insert, and a coupling surface configured to engage a complementary coupling surface of the removable insert.
- the contact surface comprises a conical surface.
- the coupling surface comprises threaded grooves.
- the inner surface further comprises a central surface between the contact surface and the coupling surface.
- the bore has a first diameter at the coupling surface, and a second diameter that is larger than the first diameter at the contact surface.
- the bore has a third diameter at the central surface, the third diameter being larger than the first diameter and smaller than the second diameter.
- the welding power supply further comprises power conversion circuitry positioned within the housing, the power conversion circuitry configured to generate welding-type output power and being in electrical communication with the socket connector.
- a removable insert for a socket of a welding power supply comprising a mechanical connector configured to mechanically connect the removable insert to a socket connector of the welding power supply, a first electrical connector configured to electrically connect the removable insert to the socket connector, and a second electrical connector configured to electrically connect the removable insert to a plug.
- the mechanical connector comprises a shoulder screw having a head, a screw thread, and a shank connecting the head to the screw thread, the screw thread configured to engage complementary threaded grooves of the socket connector.
- the first electrical connector comprises an electrically conductive frustoconical surface.
- the second electrical connector comprises a base having a keyed entryway configured to connect with a key interface of the plug.
- the keyed entryway comprises a bore encircled by an inner surface of the base, the inner surface having a keyed surface.
- the keyed surface comprises a latch that protrudes into the bore or an axial groove that expands the bore.
- Some examples of the present disclosure relate to welding-type power sockets and/or welding-type plugs that are configurable (and/or reconfigurable) through custom socket inserts, socket connectors, plug adapters, and plug receptacles.
- conventional welding-type power supplies have power sockets that are configured to connect with only one particular type of plug.
- conventional welding components have plugs configured to connect with only one particular type of power socket. Welding components having singular connection types make it difficult to connect a plug of one type to a power socket of a different type, and vice versa.
- Some examples of the present disclosure relate to inserts that may be more securely coupled to welding-type power sockets, so as to configure (and/or reconfigure) the power sockets for connection to different plug types (and/or shapes, styles, designs, etc.) with less risk of unintentional removal.
- the adapters further include different surfaces and/or structures to establish mechanical, versus electrical, connections with the power sockets. Additionally, the methods, modes, motions, and/or mediums of connection between adapter and power socket are different than that of the connection between plug and adapter. Thus, the adapters may be more securely, effectively, and/or reliably used to configure (and/or reconfigure) the plugs and/or sockets.
- FIGS. 1 and 2 show a perspective view and block diagram view, respectively, of an example of a welding-type system 10 .
- GMAW gas metal arc welding
- FCAW flux-cored arc welding
- FCAW-G gas shielded flux-cored arc welding
- GTAW gas tungsten arc welding
- SAW submerged arc welding
- SMAW shielded metal arc welding
- other metal fabrication systems such as plasma cutting systems, induction heating systems, and so forth.
- the welding-type system 10 includes a welding-type power supply 12 (i.e., a welding-type power source), a welding wire feeder 14 , a gas supply 20 , and a welding torch 16 .
- the welding-type power supply 12 generally supplies welding-type power for the various welding-type components and/or accessories of the welding-type system 10 (e.g., the welding wire feeder 14 and/or welding torch 16 ) through an electrical panel 102 of a housing 104 of the welding-type power supply.
- the electrical panel 102 is part of a front panel 106 on the housing 104 of the welding-type power supply 12 .
- the electrical panel 102 may instead be part of a rear panel, a side panel, a top panel, and/or a bottom panel of the housing 104 .
- the electrical panel 102 includes welding-type power sockets 300 .
- the sockets 300 may be configured for positive polarity and/or negative polarity.
- there may be more or less than two sockets 300 such as a single socket and/or three or more sockets.
- the sockets 300 extend through the housing 104 , such that a portion of each socket 300 is both inside and outside the housing 104 .
- the welding-type power supply 12 is coupled to the welding wire feeder 14 and work piece 26 through the power sockets 300 . More particularly, the wire feeder 14 and work piece 26 are connected to the power sockets 300 via plugs 700 . One plug 700 is connected to one or more weld cables 38 which lead to the wire feeder 14 , while another plug 700 is coupled to one or more lead cables 39 that lead to the work piece 26 through the work clamp 23 . While not specifically labeled, in some examples, the welding wire feeder 14 may include one or more sockets and/or plugs as well.
- the welding wire feeder 14 is connected to the welding torch 16 in order to supply welding wire and/or welding-type power to the welding torch 16 during operation of the welding-type system 10 .
- the welding-type power supply 12 may couple and/or directly supply welding-type power to the welding torch 16 .
- the power supply 12 is separate from the wire feeder 14 , such that the wire feeder 14 may be positioned at some distance from the power supply 12 near a welding location.
- the wire feeder 14 in some examples, may be integral with the power supply 12 . In some examples, the wire feeder 14 may be omitted from the system 10 entirely.
- the welding-type system 10 includes a gas supply 20 that may supply a shielding gas and/or shielding gas mixtures to the welding torch 16 .
- a shielding gas may refer to any gas or mixture of gases that may be provided to the arc and/or weld pool in order to provide a particular local atmosphere (e.g., shield the arc, improve arc stability, limit the formation of metal oxides, improve wetting of the metal surfaces, alter the chemistry of the weld deposit, and so forth).
- the gas supply 20 is coupled to the welding torch 16 through the wire feeder 14 via a gas conduit 42 .
- the welding wire feeder 14 may regulate the flow of gas from the gas supply 20 to the welding torch 16 .
- the gas supply 20 is depicted as coupled directly to the welding torch 16 rather than being coupled to the welding torch 16 through the wire feeder 14 .
- the gas supply 20 may be integral with or separate from the power supply 12 . In some examples, no gas supply 20 may be used.
- the welding-type power supply 12 includes an operator interface 28 , control circuitry 30 , and power conversion circuitry 32 .
- the power conversion circuitry 32 is configured to receive input power from a power source 34 (e.g., the AC power grid, an engine/generator set, or a combination thereof), and adjust the input power as appropriate for a desired welding-type application.
- a power source 34 e.g., the AC power grid, an engine/generator set, or a combination thereof
- the power conversion circuitry 32 is configured to output welding-type power to the wire feeder 14 and/or work piece 26 through the power sockets 300 .
- the control circuitry 30 may control the power conversion circuitry 32 to produce the appropriate and/or desired welding-type power.
- An operator may provide weld input and/or weld settings (e.g., regarding the appropriate and/or desired welding-type power) through the operator interface 28 .
- the power conversion circuitry 32 may include circuit elements (e.g., transformers, rectifiers, capacitors, inductors, diodes, transistors, switches, and so forth) capable of converting input power to welding-type output power.
- the welding-type output power of the power conversion circuitry 32 may comprise one or more of a direct current electrode positive (DCEP) output, direct current electrode negative (DCEN) output, DC variable polarity, and/or a variable balance (e.g., balanced or unbalanced) AC output, as dictated by the demands of the welding-type system 10 (e.g., based on the type of welding process performed by the welding-type system 10 , and so forth).
- DCEP direct current electrode positive
- DCEN direct current electrode negative
- DC variable polarity e.g., DC variable polarity
- a variable balance e.g., balanced or unbalanced
- the control circuitry 30 is configured to control the power conversion circuitry 32 using one or more control algorithms.
- the control circuitry 30 comprises one or more processors 35 and/or memory 37 .
- the one or more processors 35 may use data stored in the memory 37 to execute the control algorithms to control the power conversion circuitry 32 .
- the control circuitry 30 may use input from feedback sensors and/or an operator to control the power conversion circuitry 32 .
- the welding-type system 10 may receive weld settings from the operator via the operator interface 28 .
- control elements 29 of the operator interface 28 are provided on the front panel 106 of the housing 104 , proximate the electrical panel 102 .
- the control elements 29 may include switches, knobs, gauges, etc.
- the operator interface 28 is coupled to the control circuitry 30 , and may communicate the weld settings to the control circuitry 30 via this coupling.
- the welding-type system 10 includes one or more sensors 36 .
- the control circuitry 30 may monitor the current and/or voltage of the arc 24 using the sensors 36 .
- a first sensor 36 a is clamped to the work piece 26
- a second sensor 36 b is positioned on and/or proximate to the welding torch 16 .
- additional sensors 36 may positioned on and/or proximate the wire feeder 14 and/or weld cable 38 .
- the one or more sensors 36 may comprise, for example, current sensors, voltage sensors, impedance sensors, and/or other appropriate sensors.
- the control circuitry 30 may determine and/or control the power conversion circuitry 32 to produce an appropriate power output, arc length, and/or electrode extension based at least in part on feedback from the sensors 36 .
- the power conversion circuitry 32 may provide DC and/or AC welding-type output power via the power sockets 300 .
- the welding-type power supply 12 may power the welding wire feeder 14 that, in turn, powers the welding torch 16 , in accordance with demands of the welding-type system 10 .
- the lead cable 39 terminating in the clamp 23 couples the welding-type power supply 12 to the work piece 26 to close the circuit between the welding-type power supply 12 , the work piece 26 , and the welding torch 16 .
- An operator may engage a trigger 22 of the torch 16 to initiate an arc 24 between a wire electrode 18 fed through the torch 16 and the work piece 26 .
- engaging the trigger 22 of the torch 16 may initiate a different welding-type function, instead of an arc 24 .
- FIG. 3 a shows an exploded view of an example power socket assembly 300 .
- FIG. 3 c shows an assembled cross-sectional view of the power socket assembly 300 . While the example power socket assembly 300 shown in FIGS. 3 a and 3 c shows only the socket connector 500 a , it should be understood that socket connector 500 b could also have been used. Likewise, while the cross-section of FIG. 3 c shows only the socket insert 600 a and socket connector 500 a , any combination of socket inserts 600 and socket connectors 500 shown in FIGS. 3 a and 5 a - 6 f may be used to form the power sockets 300 in FIGS. 1 and 2 . It should be understood that the disclosed example power sockets 300 may be used to provide multiple power outputs in the electrical panel 102 . When fully assembled, the components of the power socket assembly 300 are approximately centered about a common axis 101 , as shown, for example in FIG. 3 c.
- each power socket 300 includes an insulating bulkhead 400 , an insulating cap 302 , a socket connector 500 , and a socket insert 600 .
- the insulating bulkhead 400 formed on the electrical panel 102 extends from an exterior of the housing 104 , through the electrical panel 102 , and into an interior of the housing 104 .
- the insulating cap 302 encircles the bulkhead 400 within the housing 104 (see also FIGS. 4 a and 4 b ).
- the insulating bulkhead 400 and/or insulating cap 302 may be formed of an electrically insulating material. In some examples, the bulkhead 400 and/or cap 302 may additionally, or alternatively, be formed of a thermally insulating material.
- the insulating bulkhead 400 includes a generally cylindrical exterior surface 402 extending from the electrical panel 102 on the exterior of the housing 104 .
- An interior surface 404 of the bulkhead 400 surrounds a slot 406 that extends through the electrical panel 102 and bulkhead 400 into the housing 104 .
- the interior surface 404 of the bulkhead 400 is approximately circular and/or cylindrical, with two parallel straight edge portions 408 truncating the circular/cylindrical shape.
- the resulting shape of the slot 406 is similar to the shape of a collar 502 of the socket connector 500 , so that the socket connector 500 may snugly fit within the slot 406 , as further explained below.
- the slot 406 has a diameter that decreases as the slot 406 extends inward toward the cap 302 .
- the inner surface 404 of the bulkhead 400 includes a shoulder 410 and taper 412 that narrows the diameter of the slot 406 .
- the shoulder 410 and/or taper 412 are configured to abut the collar 502 of a socket connector 500 when a socket connector 500 is inserted into the slot 406 , so as to help retain the socket connector 500 within the slot 406 and prevent the socket connector 500 from moving farther into the interior of the housing 104 .
- FIGS. 5 a - 5 d show two different example socket connectors 500 .
- the socket connectors 500 may comprise electrically conductive material, such as brass and/or copper, for example.
- the different socket connectors 500 may be used to output different power polarities, such that one socket connector 500 is used in the electrical panel 102 to output positive polarity welding-type power while the other socket connector 500 is used in the electrical panel 102 to output negative polarity welding-type power.
- two of the same socket connectors 500 may be used to output both positive and negative polarity welding-type power.
- one of the socket connector 500 may be used in the electrical panel 102 and configured to output positive or negative polarity welding-type power, while a different socket connector (not shown) may be used in the electrical panel 102 and configured to output the other polarity of welding-type power.
- the operator interface 28 may include a control element that allows for selection of power socket polarity.
- each socket connector 500 comprises an inner surface and an outer surface.
- the outer surface includes a collar 502 , a body 504 that extends from the collar 502 , and a nose 506 that extends from the body 504 .
- the collar 502 is generally circular, with two opposing and/or parallel wrench flats 508 .
- the collar 502 has a shape similar to that of the slot 406 , so as to provide a snug fit within the slot 406 .
- the collar 502 may be configured to abut the shoulder 410 and/or taper 412 of the bulkhead 400 when assembled within the slot 406 .
- the body 504 of each socket connector 500 is generally cylindrical, and includes a groove 510 in an approximate middle of the body 504 configured to fit an O-ring.
- the collar 502 has the largest outer diameter, followed by the body 504 , then the nose 506 , and then the groove 510 .
- the body 504 may be substantially and/or entirely covered by bulkhead 400 and/or cap 302 .
- the nose 506 extends forward from the body 504 , such that the nose 506 extends further into the housing 104 , beyond the cap 302 , therefore remaining uncovered within the housing 104 .
- the nose 506 includes engagement features, such as screw threads, for example.
- the engagement features of the nose 506 may be configured to engage with complementary engagement features (e.g., threaded grooves) of a nut 306 .
- the nut 306 may be combined with a washer 308 to retain the socket connector 500 within the slot 406 (in conjunction with the shoulder 410 and/or taper 412 ) and to retain the cap 302 over the bulkhead 400 and/or body 504 of the socket connector 500 .
- each socket connector 500 surrounds a bore 512 that extends through the socket connector 500 .
- the inner surface of the socket connector includes a contact surface 514 , a coupling surface 518 , and a central surface 516 .
- the contact surface 514 extends from the collar 502 into the body 504 , and terminates short of the groove 510 .
- the central surface 516 extends from the contact surface 514 towards the nose 506 .
- the coupling surface 518 extends from the central surface 516 towards a receiving surface 520 , further explained below.
- the diameter of the bore 512 is largest at the contact surface and smallest at the coupling surface 518 , with the bore 512 having a diameter at the central surface 516 that is larger than the diameter of the bore 512 at the coupling surface 518 , but smaller than the diameter of the bore 512 at the contact surface 514 .
- the contact surface 514 is configured to make electrical contact with a nose 614 of an insert 600 .
- the contact surface 514 is approximately conical (and/or frustoconical), such that the bore 512 decreases in diameter traveling from the collar 502 in towards the central surface 516 .
- the conical (and/or frustoconical) shape of the contact surface 514 provides a substantial surface area for electrical contact, and increases the likelihood of good electrical contact when an insert 600 is firmly secured to the socket connector 500 .
- the central surface 516 lies between the contact surface 514 and the coupling surface 518 .
- the central surface 516 encircles a portion of the bore 512 that is configured to fit a nut 616 of the insert 600 .
- the coupling surface 518 is configured to engage a complementary coupler 618 of the insert 600 .
- the coupling surface 518 may include engagement features, such as, for example, threaded grooves, to connect with (and/or attach to) complementary engagement features of a coupler 618 of the insert 600 .
- the inner surface of the socket connector 500 a further includes a receiving surface 520 a that is configured to receive and make contact with one or more electrical conductors (and/or wires, wiring, cables, leads, clips etc.) coming from the power conversion circuitry 32 .
- the electrical conductors may extend into the bore 512 encircled by the receiving surface 520 a so as to connect the socket connector 500 to the power conversion circuitry 32 .
- the socket connector 500 may additionally, or alternatively, be connected to the power conversion circuitry 32 via the nose 506 , which may make electrical contact with one or more electrical conductors.
- the socket connector 500 b has a different receiving surface 520 b that is part of the outer surface of the socket connector 500 b .
- the receiving surface 520 b extends from the nose 506 , and has a hole 522 that may receive a bolt or other fastener so as to couple the one or more electrical conductors to the socket connector 500 b.
- Each socket connector 500 is configured for coupling to a plurality of inserts 600 .
- three inserts 600 are shown. Any of the inserts 600 may be coupled to either socket connector 500 . In some examples, other inserts (not shown) may be coupled to the socket connectors 500 .
- Each insert 600 may be comprised of an electrically conductive material, such as brass, copper, and/or any other appropriately conductive material. As shown, each insert 600 has a “male” end with a coupler 618 for connecting to the socket connector 500 , and a “female” end with a keyed entryway 602 for connecting to a key interface 802 of a plug 700 , as discussed further below. In some examples, an insert 600 may instead include two “male” ends. However, having one end be a “male” end and the other end be a “female” end configured for connecting to the plug 700 advantageously avoids additional and/or unnecessary outcroppings on the welding-type power supply 12 and/or power supply housing 104 .
- Each “female” end keyed entryway 602 is configured to accept (and/or receive, connect with, attach to, engage with, etc.) a particular type of plug 700 that has a particular complementary (and/or matching) key interface 802 .
- the coupler 618 of each insert 600 has engagement features configured for secure external connection to the complementary engagement features of the coupling surface 518 of the socket connector 500 .
- an operator may securely and externally reconfigure a power socket 300 of a welding-type power supply 12 for a different type of plug 700 , without having to access the internals of the housing 104 , and without worrying that the insert 600 will become mechanically and/or electrically removed from the power socket 300 if/when the operator removes the plug 700 from the power socket 300 .
- each insert 600 includes body 604 and a coupler 618 .
- the body includes a base 606 and a nose 614 .
- the base 606 has an outer surface that is approximately cylindrical, with parallel and opposing flats 608 that truncate the cylinder.
- the shape of the base 606 approximates that of the slot 406 of the bulkhead 400 , so that the insert 600 may fit within the bulkhead 400 to connect with the socket connector 500 .
- the nose 614 extends from the base 606 . In the examples of FIGS.
- the nose 614 is approximately conical (and/or frustoconical), being shaped (and/or configured) to electrically contact (and/or connect) with the contact surface 514 of the socket connector 500 .
- each insert 600 includes a coupler 618 comprising a shoulder screw 610 and a nut 616 engaged to the shoulder screw 610 .
- the shoulder screw 610 includes a head 620 attached to a shank 622 .
- the shank 622 extends between the head 620 and a screw thread 624 .
- the head 620 is positioned within a recess 626 of the nose 614 , and includes a tool interface 628 configured to receive a work end of a tool, such as a screwdriver and/or Allen wrench, for example.
- an operator may insert a tool end of a tool into the tool interface 628 and turn the shoulder screw 610 via the tool and tool interface 628 connection, so as to couple and/or uncouple the screw threads 624 from the coupling surface 518 of the socket connector 500 .
- the screw threads 624 extend out of the nose 614 of the insert 600 , along with a small sliver of the shank 622 .
- the nut 616 is engaged to the screw threads 624 adjacent to the nose 614 .
- the shoulder screw 610 is not integrally connected to the rest of the insert 600 in the examples of FIGS. 3 a and 6 a - 6 f , the nut 616 ensures that body 604 is removed along with the shoulder screw 610 when removing the insert 600 from the socket connector 500 .
- the power socket 300 may undergo heating due to thermal effects of the electrical power conducted through the power socket 300 .
- the power socket 300 may eventually cool down when the welding-type system 10 and/or welding-type power supply 12 is no longer in use.
- the repeated heating and cooling may cause the nose 614 of the insert 600 to partly fuse with the contact surface 514 of the socket connector 500 .
- an operator may attempt to remove the insert 600 via the tool interface 628 of the shoulder screw 610 , and only succeed in removing the shoulder screw 610 from the body 604 of the insert 600 , while the nose 614 (and/or body 604 ) of the insert 600 remains fused to the contact surface 514 .
- the shoulder screw 610 is prohibited from being removed from the body 604 of the insert 600 .
- the mechanical force that would have removed the shoulder screw 610 from the body 604 of the insert 600 is instead applied to the nut 616 , and in turn applied by the nut 616 to the nose 614 .
- This mechanical force may help to dislodge a fused nose 614 and contact surface 514 , and allow the insert 600 to be successfully removed from the socket connector 500 .
- each insert 600 includes a keyed entryway 602 .
- Each keyed entryway 602 is configured to receive a particular key interface 802 of a plug 700 , as further discussed below.
- the keyed entryway 602 a of the insert 600 a is different from the keyed entryway 602 b of the insert 600 b , such that a plug 700 intended for insert 600 b will not work with insert 600 a , and vice versa.
- the insert 600 a is configured to work with DINSE-type plugs 700
- the insert 600 b is configured to work with TWECO-type plugs 700 .
- each keyed entryway 602 comprises a hollow opening within the interior of the base 606 , with a keyed surface that uniquely configures the opening for a particular type of plug 700 .
- the insert 600 a includes a keyed entryway 602 a .
- the keyed entryway 602 a is shorter and less wide (with a smaller diameter) than the keyed entryway 602 b in FIG. 6 d .
- the keyed entryway 602 a includes a groove 629 in the inner surface of the base 606 .
- the groove 629 comprises the keyed surface of the keyed entryway 602 a .
- the groove 629 expands the keyed entryway 602 a within the base 606 along the axial length of the keyed entryway 602 a .
- the groove 629 expands the keyed entryway 602 a , so as to increase the diameter of the keyed entryway 602 a along its axial length. As shown in FIGS. 6 a and 6 b , the groove 629 becomes slightly shallower at an inflection point 632 .
- the keyed entryway 602 also includes a second groove 634 that expands the diameter of the keyed entryway in an arc around the keyed entryway at the inflection point 632 .
- the second groove 634 provides space for a ridge 822 of a corresponding plug 700 to rotate within the keyed entryway 602 a at the inflection point 632 .
- the width of the second groove 634 may be approximately equal to (or slightly larger than) a width (and/or thickness) of the ridge 822 .
- the configuration of the keyed entryway 602 a comprises a DINSE-type (and/or style) configuration.
- a DINSE-type plug 700 would have a key interface 802 a comprising a cylindrical stem 820 with the ridge 822 , such that the stem 820 could be inserted into the keyed entryway 602 a when the ridge 822 is in alignment with the groove 629 . Thereafter, the plug 700 (and/or stem 820 ) could be turned and/or twisted within the keyed entryway 602 a to move the ridge 822 out of alignment with the groove 629 , thereby securing the plug 700 within the keyed entryway 602 a . When thus secured, the interior surface of the base 606 provides an electrical connection with the key interface 802 a of the plug 700 . The groove 629 prevents any non-DINSE plug 700 from connecting with the insert 600 a.
- the insert 600 b includes a keyed entryway 602 b with a keyed surface comprising a latch 630 that protrudes into the keyed entryway 602 b .
- the latch 630 is a protuberance that extends from an inner surface of the base 606 of the insert 600 b into the opening of the keyed entryway 602 b .
- the latch 630 lessens the diameter of the keyed entryway 602 b within the base 606 .
- the keyed entryway 602 has an approximately consistent diameter most everywhere else within the body 604 of the insert 600 b .
- the latch 630 is positioned closer to the nose 614 of the insert 600 b than the beginning of the keyed entryway 602 b .
- the configuration of the keyed entryway 602 b comprises a TWECO-type (and/or style) configuration.
- a TWECO-type plug 700 would have a key interface 802 b comprising a cylindrical stem 820 with a cutout 823 that matched the latch 630 , such that the stem 820 could be inserted into the keyed entryway 602 b at an orientation where the cutout 823 aligned with the latch 630 , so that the stem 820 could pass by the latch 630 . Thereafter, the plug 700 (and/or stem 820 ) could be turned and/or twisted within the keyed entryway 602 b to move the cutout 823 out of alignment with the latch 630 , thereby securing the plug 700 within the keyed entryway 602 b . When thus secured, the interior surface of the base 606 provides an electrical connection with the key interface 802 b of the plug 700 . The latch 630 prevents any non-TWECO-plug 700 from connecting with the insert 600 b.
- the insert 600 c includes a keyed entryway 602 c with a keyed surface comprising a pair of opposing grooves.
- Each of the grooves 652 has an inflection point 654 , similar to the groove 629 and inflection point 632 of the insert 600 a .
- the keyed entryway 602 c (and/or keyed surface) further includes threaded grooves 650 to assist with turning of a complementary plug adapter 800 c .
- shoulders 827 of a complementary plug adapter 800 c may move within the grooves 652 , until encountering the inflection points 654 , at which point the plug adapter 800 c may be turned to take the shoulders 827 out of alignment with the grooves 652 .
- one or more of the inflection points 654 may be omitted from the insert 600 c.
- the plug adapter 800 c may have a key interface 802 similar to the stem portion described in U.S. Pat. No. 7,377,825, which is owned by the assignee of the present application, and hereby incorporated by reference.
- the insert 600 c may have a base 606 similar to portions of the receptacle U.S. Pat. No. 7,377,825.
- FIGS. 7 a and 7 b show examples of welding-type power plug assemblies 700 , 701 .
- the plug assembly 700 in FIG. 7 a may be considered a “male” plug assembly 700
- the plug assembly 701 in FIG. 7 b may be considered a “female” plug assembly 701 .
- the plug assembly 700 includes a plug adapter 800 , a plug receptacle 900 , and a plug cover 702 .
- the plug assembly 701 includes a plug adapter 801 , a plug receptacle 900 , and a plug cover 702 .
- the plug adapters 800 , 801 and plug receptacle 900 may be comprised of electrically conductive material, such as brass and/or copper, for example.
- the plug cover 702 may be comprised of an electrically and/or thermally insulating material (e.g., rubber), so as to allow an operator to grasp the plug assembly 700 during operation.
- the plug cover 702 encloses the plug receptacle 900 and much of the plug adapter 800 , 801 when the plug assembly 700 is assembled together.
- portions of the plug adapter 800 , 801 may extend beyond the plug cover 702 when the plug assembly 700 , 701 is assembled.
- the plug cover 702 may encircle the entirety of the plug adapter 800 , 801 when the plug assembly 700 , 701 is assembled.
- FIGS. 7 a , 7 b , 9 a , and 9 b show an example receptacle 900 .
- the receptacle 900 includes an outer surface and an inner surface.
- the outer surface includes a base 902 and a tube 904 .
- both the base 902 and tube 904 are approximately cylindrical.
- the base 902 has opposing wrench flats 908 that truncate the cylindrical shape of the base.
- the base 902 includes cap screw holes 910 on opposing sides of the base 902 .
- the tube 904 includes axially aligned set screw holes 912 .
- the surfaces encircling the set screw holes 912 and/or cap screw holes 910 may be formed with threaded grooves to engage the screws.
- the inner surface of the receptacle 900 encircles a conduit 914 that extends through the receptacle 900 .
- the inner surface includes an adapter interface 916 , a tail interface 918 and a cable interface 920 .
- the diameter of the conduit 914 is largest at the beginning of the adapter interface 916 , then narrows to a smaller diameter within the tail interface 918 , before expanding again within the cable interface 920 .
- the adapter interface 916 is shaped approximately conically (and/or frustoconically) and is configured to contact, connect, and/or interface with the receptacle interface 806 of the plug adapter 800 , so as to establish an electrical connection between the plug adapter 800 and the receptacle 900 .
- the diameter of the conduit 914 at the widest point within the adapter interface 916 is smaller than the diameter of a central disc 804 of the plug adapter 800 (and/or body 604 of the plug adapter 801 ), such that the central disc 804 will not fit within the conduit 914 .
- the plug receptacle 900 includes opposing cap screw holes 910 in the outer surface that lead to the tail interface 918 .
- the tail interface 918 is approximately cylindrical.
- the tail interface 918 may be formed with engagement features, such as threaded grooves, for example, to engage complementary engagement features on the tail 818 .
- the cap screw holes 910 may align with complementarily shaped and/or sized cap screw holes 704 in the plug cover 702 to receive cap screws 710 , such as nylon cap screws, for example.
- the cap screws 710 may be formed of some other electrically and/or thermally insulating material.
- the surface of the receptacle 900 surrounding the cap screw holes 910 may include threaded grooves to receive the cap screws 710 .
- the cap screws 710 may assist in frictionally retaining the tail 818 within the conduit 914 encircled by the tail interface 918 .
- the plug receptacle 900 further includes set screw holes 912 that lead to the cable interface 920 .
- the cable interface 920 is approximately cylindrical.
- the set screw holes 912 may be encircled by threaded grooves, to receive set screws 712 .
- the set screws 712 may be formed of electrically conductive material, such as a metallic material, for example.
- plug adapters 800 a - 800 c include “male” style key interfaces 802 .
- the plug adapters 801 a - 801 c include “female” style key entryways 602 , similar to the key entryways 602 of the socket inserts 600 .
- FIG. 10 b shows an example assembled plug assembly 700 with the plug adapter 800 a .
- FIG. 10 c shows an example assembled plug assembly 701 with the plug adapter 801 a . It should be understood that any of the plug adapters 800 , 801 could be interchanged with the plug adapters 800 a , 801 a in FIGS. 10 b and 10 c , and/or otherwise used with the socket assembly 700 .
- the plug adapters 800 include a central disc 804 having wrench flats 808 that may be used by a wrench (and/or other appropriate tool) to connect and/or disconnect the plug adapter 800 to/from the plug receptacle 900 .
- the plug adapter 800 further includes a key interface 802 , a receptacle interface 806 , and a tail 818 .
- the key interface 802 and receptacle interface 806 extend from opposite faces of the central disc 804 .
- the receptacle interface 806 is a conical (and/or frustoconical) surface.
- the receptacle interface 806 is configured to electrically contact, connect to, and/or interface with a complementary surface in the plug receptacle 900 , so as to establish an electrical connection with the plug receptacle 900 , through which electrical power may flow.
- the receptacle interface 806 and the tail 818 connect at an end opposite of the key interface 802 .
- the tail 818 is approximately cylindrical, with an outer diameter slightly less than the stem 820 of the key interface 802 .
- the tail 818 may be formed with engagement features, such as screw threads, for example.
- the tail 818 may be configured to engage with the tail interface 918 of the receptacle 900 , such as through complementary engagement features (e.g., threaded grooves) of the tail interface 918 .
- the tail 818 and tail interface 918 (with or without with cap screws 710 ) may allow an operator to securely connect the plug adapter 800 to, and disconnect the plug adapter from, the receptacle 900 , as desired.
- the key interface 802 a of the plug adapter 802 a comprises a cylindrical stem 820 with a key interface feature.
- the key interface feature comprises a ridge 822 that protrudes radially away from the body.
- the ridge 822 is sized, shaped, and/or otherwise configured to fit through the groove 629 of the keyed entryway 602 a .
- the plug assembly 700 may be connected with the socket 300 by inserting the key interface 802 into the keyed entryway 602 a of the insert 600 , whereby the ridge 822 will move through the groove 629 until the ridge 822 hits the inflection point 632 .
- the plug assembly 700 may be turned and/or twisted to move the ridge 822 through the second groove 634 , to a point where the ridge 822 is out of alignment with the groove 632 a . Once the ridge 822 is out of alignment with the groove 632 a , the plug assembly 700 may not be removed from the socket 300 without moving the ridge 822 back into alignment.
- FIGS. 8 d - 8 i show example plug adapters 800 b and 800 c with different key interface features.
- the plug adapter 800 b includes a key interface 802 b with a key interface feature comprising a cutout 823 in the stem 820 of the key interface 802 .
- the cutout 823 results in a flat surface 824 that extends from an end 826 of the key interface 802 b to a semicircular wall 829 .
- the cutout 823 further forms an annular channel 830 that circles part of the flat surface 826 , forming a hook 832 .
- the cutout 823 is configured to allow the key interface 802 to proceed past the latch 630 in the keyed entryway 602 b .
- the annular channel 830 provides a path for the latch 630 when the key interface 802 rotates within the keyed entryway 602 . After rotation, the cutout 823 will be out of alignment with the latch 630 , and the hook 832 will grasp the latch 630 , so that the key interface 802 may not be withdrawn from the keyed entryway 602 .
- the plug adapter 800 c includes a key interface 802 c with a stem 820 that is not completely cylindrical. Rather, the stem 820 includes flat sides 828 that truncate the otherwise cylindrical stem 820 . The cylindrical portions of the stem 820 are formed with screw threads 834 . Extending from the stem 820 is a key interface feature comprising a pair of opposing shoulders 827 formed on opposite sides of the cylindrical portions of the stem 820 . The shoulders 827 are configured to pass through a pair of opposing grooves 652 in a keyed entryway 602 c of the insert 600 c (and/or plug adapter 801 c ). In some examples, the plug adapter 800 may have a key interface 802 similar to the stem portion described in U.S. Pat. No. 7,377,825, which is owned by the assignee of the present application, and hereby incorporated by reference.
- FIGS. 7 b and 8 j - 8 r show plug adapters 801 that have a “female” keyed entryway 602 , similar to the keyed entryways 602 of the socket inserts 600 .
- the plug adapters 801 share features with both the socket inserts 600 and the plug adapters 800 .
- the plug adapters 801 still have the tail 818 and receptacle interface 806 (and/or nose 614 ), but no central disc 804 or key interface 802 .
- the plug adapter 800 has a body 604 comprising of a base 606 with a keyed entryway 602 , similar to that of the inserts 600 . As all of these features were previously described, they will not be enumerated again here.
- FIG. 11 shows an example method 1100 for configuring and/or reconfiguring a welding-type power socket 300 and/or plug assembly 700 for welding-type operation. While the disclosure refers to an operator, it should be understood that, in some examples, an automated machine, such as a robot for example, may take the role of an operator.
- the method 1100 begins at block 1102 , assuming that the plug assembly 700 is disconnected from the power socket 300 , and the one or more socket connectors 500 are firmly attached within the bulkheads 400 of the electrical panel 102 of the welding-type power supply 12 .
- the operator may attach one of the inserts 600 to the socket connector 500 , if desired, such as by securely coupling the coupler 618 of the insert 600 to the coupling surface 518 of the socket connector 500 .
- the operator may attach one of the plug adapters 800 , 801 to the plug receptacle 900 , such as by connecting the tail 818 of the plug adapter 800 to the tail interface 918 of the plug receptacle 900 , and further tightening the cap screws 710 .
- the operator will attach an insert 600 with a keyed entryway 602 that corresponds to the key interface 802 of the plug adapter 800 being attached to the plug receptacle 900 .
- blocks 1104 and/or 1106 may be skipped if the correct and/or desired socket insert(s) 600 and/or plug adapter(s) 800 are already attached.
- the plug assembly 700 is connected to the power socket 300 by inserting the key interface 802 into the keyed entryway 602 and twisting and/or turning the plug assembly, so as to move the key interface 802 into a locking arrangement with the keyed entryway 602 , with the key interface feature out of alignment with the keyed surface.
- the operator may determine whether a good connection has been made. If not, the method 1100 proceeds to block 1112 , discussed further below. If so, the method proceeds to block 1114 , where a welding operation may take place, using the welding-type power flowing from the welding-type power supply 12 , through the connection between the welding-type power socket 300 and the plug assembly 700 and to the appropriate welding component.
- the welding cable 1000 may lead to another plug assembly 700 having a “female” plug adapter 800 , which may in turn be attached to another plug assembly 700 having a “male” plug adapter 800 , and so on in a daisy chain and/or extension fashion until the welding cable 1000 terminates in a welding component.
- the operator may determine whether the welding type operation is finished. If not, block 1114 continues and/or repeats. If so, the method 1100 proceeds to block 1112 , where the operator may disconnect the plug assembly 700 from the power socket 300 . In some examples, this block may be skipped if further welding-type operations are planned for the near future. The method 1100 then proceeds to block 1118 , where the operator may remove the insert 600 and/or plug adapter 800 from the power socket 300 and/or plug assembly 700 , if so desired. In some examples, this block 1118 may be skipped if, for example, further welding-type operations are planned in the near future using the currently attached insert 600 and/or plug adapter 800 . The method once again ends/begins at block 1102 .
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Abstract
In some examples, apparatuses, systems, and/or methods for configuring and/or reconfiguring welding-type power sockets and/or welding-type plugs may include welding-type power sockets and/or welding-type plugs that may be configurable (and/or reconfigurable) through custom socket inserts, socket connectors, plug adapters, and plug receptacles.
Description
- This application is a continuation of, and claims priority to, co-pending U.S. patent application Ser. No. 16/033,922, filed Jul. 12, 2018, entitled “Reconfigurable Welding-Type Power Sockets and Power Plugs,” the entire contents of which are hereby incorporated by reference.
- The present disclosure generally relates to welding-type systems, and more particularly to welding-type power sockets and power plugs that are configurable (and/or reconfigurable).
- Some welding systems include welding components (e.g., torch, clamp, wire feeder, etc.) that are powered by a welding power supply. Power is transferred from a welding power supply to a welding component via a cable connection with a power socket of the power supply, such as through a plug end of the cable. However, some power supplies have power sockets that are configured to connect only with one particular type of plug and/or cable. This may make it difficult to connect one type of plug to a power socket designed for a different type of plug.
- Limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with the present disclosure as set forth in the remainder of the present application with reference to the drawings.
- The present disclosure is directed to welding-type power sockets and plugs that are configurable (and/or reconfigurable), for example, substantially as illustrated by and/or described in connection with at least one of the figures, and as set forth more completely in the claims.
- These and other advantages, aspects and novel features of the present disclosure, as well as details of an illustrated example thereof, will be more fully understood from the following description and drawings.
-
FIG. 1 illustrates an example of a welding-type system, in accordance with aspects of this disclosure. -
FIG. 2 is a block diagram of the example welding-type system ofFIG. 1 , in accordance with aspects of this disclosure. -
FIG. 3 a is a perspective exploded view of an example welding-type power socket, in accordance with aspects of this disclosure. -
FIG. 3 b is a front view of the example welding-type power socket ofFIG. 3 a with one of the socket inserts ofFIG. 3 a , in accordance with aspects of this disclosure. -
FIG. 3 c is a cross-section of the example welding type power socket ofFIG. 3 b , along theline 3 c-3 c inFIG. 3 b , in accordance with aspects of this disclosure -
FIG. 4 a is a front view of an example bulkhead, in accordance with aspects of this disclosure. -
FIG. 4 b is a cross-section of the example bulkhead ofFIG. 4 a , along theline 4 b-4 b ofFIG. 4 a , in accordance with aspects of this disclosure. -
FIG. 5 a is a front view of an example socket connector, in accordance with aspects of this disclosure. -
FIG. 5 b is a cross-section of the example socket connector ofFIG. 5 a , along theline 5 b-5 b ofFIG. 5 b , in accordance with aspects of this disclosure. -
FIG. 5 c is a front view of another example socket connector, in accordance with aspects of this disclosure. -
FIG. 5 d is a cross-section of the example socket connector ofFIG. 5 d , along theline 5 d-5 d inFIG. 5 c , in accordance with aspects of this disclosure. -
FIG. 6 a is a front view of an example insert, in accordance with aspects of this disclosure. -
FIG. 6 b is a cross-section of the example insert ofFIG. 6 a , along theline 6 b-6 b ofFIG. 6 a , in accordance with aspects of this disclosure. -
FIG. 6 c is a front view of another example insert, in accordance with aspects of this disclosure. -
FIG. 6 d is a cross-section of the example insert ofFIG. 6 c , along theline 6 d-6 d ofFIG. 6 c , in accordance with aspects of this disclosure. -
FIG. 6 e is a front view of another example insert, in accordance with aspects of this disclosure. -
FIG. 6 f is a cross-section of the example insert ofFIG. 6 e , along theline 6 f-6 f ofFIG. 6 e , in accordance with aspects of this disclosure. -
FIG. 7 a is a perspective exploded view of an example plug assembly, in accordance with aspects of this disclosure. -
FIG. 7 b is a perspective exploded view of another example plug assembly, in accordance with aspects of this disclosure. -
FIG. 8 a is a perspective view of an example plug adapter, in accordance with aspects of this disclosure. -
FIG. 8 b is a front view of the example plug adapter ofFIG. 8 a , in accordance with aspects of this disclosure. -
FIG. 8 c is a cross-section of the example plug adapter ofFIG. 8 b , along theline 8 c-8 c ofFIG. 8 b , in accordance with aspects of this disclosure. -
FIG. 8 d is a perspective view of another example plug adapter, in accordance with aspects of this disclosure. -
FIG. 8 e is a front view of the example plug adapter ofFIG. 8 d , in accordance with aspects of this disclosure. -
FIG. 8 f is a cross-section of the example plug adapter ofFIG. 8 e , along theline 8 f-8 f ofFIG. 8 e , in accordance with aspects of this disclosure. -
FIG. 8 g is a perspective view of another example plug adapter, in accordance with aspects of this disclosure. -
FIG. 8 h is a front view of the example plug adapter ofFIG. 8 g , in accordance with aspects of this disclosure. -
FIG. 8 i is a cross-section of the example plug adapter ofFIG. 8 b , along theline 8 c-8 c ofFIG. 8 b , in accordance with aspects of this disclosure. -
FIG. 8 j is a perspective view of another example plug adapter, in accordance with aspects of this disclosure. -
FIG. 8 k is a front view of the example plug adapter ofFIG. 8 j , in accordance with aspects of this disclosure. -
FIG. 8 l is a cross-section of the example plug adapter ofFIG. 8 k , along the line 81-81 ofFIG. 8 k , in accordance with aspects of this disclosure. -
FIG. 8 m is a perspective view of another example plug adapter, in accordance with aspects of this disclosure. -
FIG. 8 n is a front view of the example plug adapter ofFIG. 8 m , in accordance with aspects of this disclosure. -
FIG. 8 o is a cross-section of the example plug adapter ofFIG. 8 n , along the line 8 o-8 o ofFIG. 8 n , in accordance with aspects of this disclosure. -
FIG. 8 p is a perspective view of another example plug adapter, in accordance with aspects of this disclosure. -
FIG. 8 q is a front view of the example plug adapter ofFIG. 8 p , in accordance with aspects of this disclosure. -
FIG. 8 r is a cross-section of the example plug adapter ofFIG. 8 q , along theline 8 r-8 r ofFIG. 8 q , in accordance with aspects of this disclosure. -
FIG. 9 a is a front view of an example plug receptacle, in accordance with aspects of this disclosure. -
FIG. 9 b is a cross-section of the example plug receptacle ofFIG. 9 a , along theline 9 b-9 b ofFIG. 9 a , in accordance with aspects of this disclosure. -
FIG. 10 a is a front view of the plug assembly ofFIG. 7 a , with one of the plug adapters ofFIG. 7 a , in accordance with aspects of this disclosure. -
FIG. 10 b is a cross-section of the plug assembly ofFIG. 10 a , along theline 10 b-10 b inFIG. 10 a , in accordance with aspects of this disclosure. -
FIG. 10 c is a cross section of the plug assembly ofFIG. 7 b , with one of the plug adapters ofFIG. 7 b , in accordance with aspects of this disclosure. -
FIG. 11 is a flow diagram illustrating an example method of operation, in accordance with aspects of this disclosure. - The figures are not necessarily to scale. Where appropriate, similar or identical reference numerals are used to refer to similar or identical components. For example, reference numerals utilizing lettering (e.g.,
socket connector 500 a,socket connector 500 b) refer to instances of the same reference numeral that does not have the lettering (e.g., socket connectors 500). - Preferred examples of the present disclosure may be described hereinbelow with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail because they may obscure the disclosure in unnecessary detail. For this disclosure, the following terms and definitions shall apply.
- As used herein, the terms “about” and/or “approximately,” when used to modify or describe a value (or range of values), position, orientation, and/or action, mean reasonably close to that value, range of values, position, orientation, and/or action. Thus, the examples described herein are not limited to only the recited values, ranges of values, positions, orientations, and/or actions but rather should include reasonably workable deviations.
- As utilized herein, the terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations.
- As used herein, “and/or” means any one or more of the items in the list joined by “and/or”. As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and/or y” means “one or both of x and y”. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means “one or more of x, y and z”.
- As used herein, the terms “coupled,” “coupled to,” and “coupled with,” each mean a structural and/or electrical connection, whether attached, affixed, connected, joined, fastened, linked, and/or otherwise secured. As used herein, the term “attach” means to affix, couple, connect, join, fasten, link, and/or otherwise secure. As used herein, the term “connect” means to attach, affix, couple, join, fasten, link, and/or otherwise secure.
- As used herein the terms “circuits” and “circuitry” refer to physical electronic components (i.e., hardware) and any software and/or firmware (“code”) which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware. As used herein, for example, a particular processor and memory may comprise a first “circuit” when executing a first one or more lines of code and may comprise a second “circuit” when executing a second one or more lines of code. As utilized herein, circuitry is “operable” and/or “configured” to perform a function whenever the circuitry comprises the necessary hardware and/or code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).
- As used herein, a control circuit may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, DSPs, etc., software, hardware and/or firmware, located on one or more boards, that form part or all of a controller, and/or are used to control a welding process, and/or a device such as a power source or wire feeder.
- As used, herein, the term “memory” and/or “memory device” means computer hardware or circuitry to store information for use by a processor and/or other digital device. The memory and/or memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like.
- As used herein, the term “processor” means processing devices, apparatuses, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable. The term “processor” as used herein includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC). The processor may be coupled to, or integrated with a memory device.
- The term “power” is used throughout this specification for convenience, but also includes related measures such as energy, current, voltage, and enthalpy. For example, controlling “power” may involve controlling voltage, current, energy, and/or enthalpy, and/or controlling based on “power” may involve controlling based on voltage, current, energy, and/or enthalpy.
- As used herein, welding-type power refers to power suitable for welding, cladding, brazing, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding), carbon arc cutting or gouging, and/or resistive preheating.
- As used herein, a welding-type power supply and/or power source refers to any device capable of, when power is applied thereto, supplying welding, cladding, brazing, plasma cutting, induction heating, laser (including laser welding, laser hybrid, and laser cladding), carbon arc cutting or gouging and/or resistive preheating, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.
- Some examples of the present disclosure relate to a removable insert for a socket of a welding power supply, comprising a base having a keyed entryway configured to connect with a key interface of a plug, a nose comprising a contact surface configured to make electrical contact with a complementary contact surface of a socket connector, and a coupler configured to couple the removable insert to the socket connector.
- In some examples, the keyed entryway comprises a bore encircled by an inner surface of the base, the inner surface having a keyed surface. In some examples, the keyed surface comprises a latch that protrudes into the bore or an axial groove that expands the bore. In some examples, the contact surface comprises a frustoconical surface. In some examples, the coupler comprises a shoulder screw having a head, a screw thread, and a shank connecting the head to the screw thread, the screw thread configured to engage complementary threaded grooves of the socket connector. In some examples, the head of the shoulder screw is positioned within the nose, the head having a tool interface configured for coupling to a tool. In some examples, the coupler further comprises a nut engaged to the screw thread.
- Some examples of the present disclosure relate to a welding power supply, comprising a housing having an electrical panel with an insulating bulkhead, and a socket connector within the insulating bulkhead, the socket connector comprising a bore encircled by an inner surface, the inner surface comprising a contact surface configured to make electrical contact with a complementary contact surface of a removable insert, and a coupling surface configured to engage a complementary coupling surface of the removable insert.
- In some examples, the contact surface comprises a conical surface. In some examples, the coupling surface comprises threaded grooves. In some examples, the inner surface further comprises a central surface between the contact surface and the coupling surface. In some examples, the bore has a first diameter at the coupling surface, and a second diameter that is larger than the first diameter at the contact surface. In some examples, the bore has a third diameter at the central surface, the third diameter being larger than the first diameter and smaller than the second diameter. In some examples, the welding power supply further comprises power conversion circuitry positioned within the housing, the power conversion circuitry configured to generate welding-type output power and being in electrical communication with the socket connector.
- Some examples of the present disclosure relate to a removable insert for a socket of a welding power supply, comprising a mechanical connector configured to mechanically connect the removable insert to a socket connector of the welding power supply, a first electrical connector configured to electrically connect the removable insert to the socket connector, and a second electrical connector configured to electrically connect the removable insert to a plug.
- In some examples, the mechanical connector comprises a shoulder screw having a head, a screw thread, and a shank connecting the head to the screw thread, the screw thread configured to engage complementary threaded grooves of the socket connector. In some examples, the first electrical connector comprises an electrically conductive frustoconical surface. In some examples, the second electrical connector comprises a base having a keyed entryway configured to connect with a key interface of the plug. In some examples, the keyed entryway comprises a bore encircled by an inner surface of the base, the inner surface having a keyed surface. In some examples, the keyed surface comprises a latch that protrudes into the bore or an axial groove that expands the bore.
- Some examples of the present disclosure relate to welding-type power sockets and/or welding-type plugs that are configurable (and/or reconfigurable) through custom socket inserts, socket connectors, plug adapters, and plug receptacles. Currently, conventional welding-type power supplies have power sockets that are configured to connect with only one particular type of plug. Likewise, conventional welding components have plugs configured to connect with only one particular type of power socket. Welding components having singular connection types make it difficult to connect a plug of one type to a power socket of a different type, and vice versa.
- While it is possible to take apart a welding-type power supply and reconfigure the power sockets internally to work with a different type and/or style of plug, such an internal reconfiguration can be difficult, and/or time consuming. Devices do exist for external reconfiguration of welding-type power sockets. However, these devices often only loosely connect to the power sockets. Thus, when a plug is connected to a power socket through the device, the plug may be more securely coupled to the device than the device is coupled to the power socket, resulting in unintentional removal of the device from the power socket when the plug is removed from the power sockets. This risk of unintentional removal may be increased where the device and plug are attached and/or removed using the same or similar motion. Further, the devices tend to use the same structures and/or surfaces to establish both a mechanical and electrical connection with the power sockets. Therefore, a loose mechanical connection may also result in a loose and/or unreliable electrical connection.
- Some examples of the present disclosure, therefore, relate to inserts that may be more securely coupled to welding-type power sockets, so as to configure (and/or reconfigure) the power sockets for connection to different plug types (and/or shapes, styles, designs, etc.) with less risk of unintentional removal. The adapters further include different surfaces and/or structures to establish mechanical, versus electrical, connections with the power sockets. Additionally, the methods, modes, motions, and/or mediums of connection between adapter and power socket are different than that of the connection between plug and adapter. Thus, the adapters may be more securely, effectively, and/or reliably used to configure (and/or reconfigure) the plugs and/or sockets.
-
FIGS. 1 and 2 show a perspective view and block diagram view, respectively, of an example of a welding-type system 10. It should be appreciated that, while the example welding-type system 10 shown inFIGS. 1 and 2 may be described as a gas metal arc welding (GMAW) system, the presently disclosed system may also be used with other arc welding processes (e.g., flux-cored arc welding (FCAW), gas shielded flux-cored arc welding (FCAW-G), gas tungsten arc welding (GTAW), submerged arc welding (SAW), shielded metal arc welding (SMAW), or similar arc welding processes) or other metal fabrication systems, such as plasma cutting systems, induction heating systems, and so forth. - In the example of
FIGS. 1 and 2 , the welding-type system 10 includes a welding-type power supply 12 (i.e., a welding-type power source), awelding wire feeder 14, agas supply 20, and awelding torch 16. The welding-type power supply 12 generally supplies welding-type power for the various welding-type components and/or accessories of the welding-type system 10 (e.g., thewelding wire feeder 14 and/or welding torch 16) through anelectrical panel 102 of ahousing 104 of the welding-type power supply. In the example ofFIG. 1 , theelectrical panel 102 is part of afront panel 106 on thehousing 104 of the welding-type power supply 12. In some examples, theelectrical panel 102 may instead be part of a rear panel, a side panel, a top panel, and/or a bottom panel of thehousing 104. - As shown in the examples of
FIGS. 1 and 2 , theelectrical panel 102 includes welding-type power sockets 300. As shown, two of thepower sockets 300 are connected to power plugs 700. Thesockets 300 may be configured for positive polarity and/or negative polarity. In the example ofFIG. 1 , there is also a third (unlabeled) socket between thesockets 300. In some examples, there may be more or less than twosockets 300, such as a single socket and/or three or more sockets. In the example ofFIG. 2 , thesockets 300 extend through thehousing 104, such that a portion of eachsocket 300 is both inside and outside thehousing 104. - In the example of
FIGS. 1 and 2 , the welding-type power supply 12 is coupled to thewelding wire feeder 14 andwork piece 26 through thepower sockets 300. More particularly, thewire feeder 14 andwork piece 26 are connected to thepower sockets 300 viaplugs 700. Oneplug 700 is connected to one ormore weld cables 38 which lead to thewire feeder 14, while anotherplug 700 is coupled to one or morelead cables 39 that lead to thework piece 26 through thework clamp 23. While not specifically labeled, in some examples, thewelding wire feeder 14 may include one or more sockets and/or plugs as well. - In the illustrated examples, the
welding wire feeder 14 is connected to thewelding torch 16 in order to supply welding wire and/or welding-type power to thewelding torch 16 during operation of the welding-type system 10. In some examples, the welding-type power supply 12 may couple and/or directly supply welding-type power to thewelding torch 16. In the illustrated example, thepower supply 12 is separate from thewire feeder 14, such that thewire feeder 14 may be positioned at some distance from thepower supply 12 near a welding location. However, it should be understood that thewire feeder 14, in some examples, may be integral with thepower supply 12. In some examples, thewire feeder 14 may be omitted from thesystem 10 entirely. - In the examples of
FIGS. 1 and 2 , the welding-type system 10 includes agas supply 20 that may supply a shielding gas and/or shielding gas mixtures to thewelding torch 16. A shielding gas, as used herein, may refer to any gas or mixture of gases that may be provided to the arc and/or weld pool in order to provide a particular local atmosphere (e.g., shield the arc, improve arc stability, limit the formation of metal oxides, improve wetting of the metal surfaces, alter the chemistry of the weld deposit, and so forth). In the example ofFIG. 1 , thegas supply 20 is coupled to thewelding torch 16 through thewire feeder 14 via agas conduit 42. In such an example, thewelding wire feeder 14 may regulate the flow of gas from thegas supply 20 to thewelding torch 16. In the example ofFIG. 2 , thegas supply 20 is depicted as coupled directly to thewelding torch 16 rather than being coupled to thewelding torch 16 through thewire feeder 14. Thegas supply 20 may be integral with or separate from thepower supply 12. In some examples, nogas supply 20 may be used. - In the example of
FIG. 2 , the welding-type power supply 12 includes anoperator interface 28,control circuitry 30, andpower conversion circuitry 32. Thepower conversion circuitry 32 is configured to receive input power from a power source 34 (e.g., the AC power grid, an engine/generator set, or a combination thereof), and adjust the input power as appropriate for a desired welding-type application. Though thepower source 34 is shown inFIG. 2 as being outside thehousing 104, in some examples thepower source 34 may be internal to thehousing 104. Thepower conversion circuitry 32 is configured to output welding-type power to thewire feeder 14 and/orwork piece 26 through thepower sockets 300. Thecontrol circuitry 30 may control thepower conversion circuitry 32 to produce the appropriate and/or desired welding-type power. An operator may provide weld input and/or weld settings (e.g., regarding the appropriate and/or desired welding-type power) through theoperator interface 28. - The
power conversion circuitry 32 may include circuit elements (e.g., transformers, rectifiers, capacitors, inductors, diodes, transistors, switches, and so forth) capable of converting input power to welding-type output power. In some examples, the welding-type output power of thepower conversion circuitry 32 may comprise one or more of a direct current electrode positive (DCEP) output, direct current electrode negative (DCEN) output, DC variable polarity, and/or a variable balance (e.g., balanced or unbalanced) AC output, as dictated by the demands of the welding-type system 10 (e.g., based on the type of welding process performed by the welding-type system 10, and so forth). - The
control circuitry 30 is configured to control thepower conversion circuitry 32 using one or more control algorithms. In the example ofFIG. 2 , thecontrol circuitry 30 comprises one ormore processors 35 and/or memory 37. The one ormore processors 35 may use data stored in the memory 37 to execute the control algorithms to control thepower conversion circuitry 32. In some examples, thecontrol circuitry 30 may use input from feedback sensors and/or an operator to control thepower conversion circuitry 32. - In some examples, the welding-
type system 10 may receive weld settings from the operator via theoperator interface 28. In the example ofFIG. 1 ,control elements 29 of theoperator interface 28 are provided on thefront panel 106 of thehousing 104, proximate theelectrical panel 102. As shown, thecontrol elements 29 may include switches, knobs, gauges, etc. In the example ofFIG. 2 , theoperator interface 28 is coupled to thecontrol circuitry 30, and may communicate the weld settings to thecontrol circuitry 30 via this coupling. - In the example of
FIGS. 1 and 2 , the welding-type system 10 includes one or more sensors 36. Thecontrol circuitry 30 may monitor the current and/or voltage of thearc 24 using the sensors 36. In the examples ofFIGS. 1 and 2 , afirst sensor 36 a is clamped to thework piece 26, and asecond sensor 36 b is positioned on and/or proximate to thewelding torch 16. In some examples, additional sensors 36 may positioned on and/or proximate thewire feeder 14 and/orweld cable 38. The one or more sensors 36 may comprise, for example, current sensors, voltage sensors, impedance sensors, and/or other appropriate sensors. In some examples, thecontrol circuitry 30 may determine and/or control thepower conversion circuitry 32 to produce an appropriate power output, arc length, and/or electrode extension based at least in part on feedback from the sensors 36. - The
power conversion circuitry 32 may provide DC and/or AC welding-type output power via thepower sockets 300. As such, the welding-type power supply 12 may power thewelding wire feeder 14 that, in turn, powers thewelding torch 16, in accordance with demands of the welding-type system 10. Thelead cable 39 terminating in theclamp 23 couples the welding-type power supply 12 to thework piece 26 to close the circuit between the welding-type power supply 12, thework piece 26, and thewelding torch 16. An operator may engage a trigger 22 of thetorch 16 to initiate anarc 24 between awire electrode 18 fed through thetorch 16 and thework piece 26. In some examples, engaging the trigger 22 of thetorch 16 may initiate a different welding-type function, instead of anarc 24. -
FIG. 3 a shows an exploded view of an examplepower socket assembly 300.FIG. 3 c shows an assembled cross-sectional view of thepower socket assembly 300. While the examplepower socket assembly 300 shown inFIGS. 3 a and 3 c shows only thesocket connector 500 a, it should be understood thatsocket connector 500 b could also have been used. Likewise, while the cross-section ofFIG. 3 c shows only thesocket insert 600 a andsocket connector 500 a, any combination of socket inserts 600 and socket connectors 500 shown inFIGS. 3 a and 5 a-6 f may be used to form thepower sockets 300 inFIGS. 1 and 2 . It should be understood that the disclosedexample power sockets 300 may be used to provide multiple power outputs in theelectrical panel 102. When fully assembled, the components of thepower socket assembly 300 are approximately centered about acommon axis 101, as shown, for example inFIG. 3 c. - In the examples of
FIGS. 3 a-3 c , eachpower socket 300 includes an insulatingbulkhead 400, an insulatingcap 302, a socket connector 500, and a socket insert 600. The insulatingbulkhead 400 formed on theelectrical panel 102 extends from an exterior of thehousing 104, through theelectrical panel 102, and into an interior of thehousing 104. The insulatingcap 302 encircles thebulkhead 400 within the housing 104 (see alsoFIGS. 4 a and 4 b ). The insulatingbulkhead 400 and/or insulatingcap 302 may be formed of an electrically insulating material. In some examples, thebulkhead 400 and/orcap 302 may additionally, or alternatively, be formed of a thermally insulating material. - In the examples of
FIGS. 3 a-4 b , the insulatingbulkhead 400 includes a generally cylindricalexterior surface 402 extending from theelectrical panel 102 on the exterior of thehousing 104. Aninterior surface 404 of thebulkhead 400 surrounds aslot 406 that extends through theelectrical panel 102 andbulkhead 400 into thehousing 104. Theinterior surface 404 of thebulkhead 400 is approximately circular and/or cylindrical, with two parallelstraight edge portions 408 truncating the circular/cylindrical shape. The resulting shape of theslot 406 is similar to the shape of acollar 502 of the socket connector 500, so that the socket connector 500 may snugly fit within theslot 406, as further explained below. - As may be seen, for example, in
FIG. 4 b , theslot 406 has a diameter that decreases as theslot 406 extends inward toward thecap 302. More particularly, theinner surface 404 of thebulkhead 400 includes ashoulder 410 and taper 412 that narrows the diameter of theslot 406. Theshoulder 410 and/or taper 412 are configured to abut thecollar 502 of a socket connector 500 when a socket connector 500 is inserted into theslot 406, so as to help retain the socket connector 500 within theslot 406 and prevent the socket connector 500 from moving farther into the interior of thehousing 104. -
FIGS. 5 a-5 d show two different example socket connectors 500. The socket connectors 500 may comprise electrically conductive material, such as brass and/or copper, for example. In some examples, the different socket connectors 500 may be used to output different power polarities, such that one socket connector 500 is used in theelectrical panel 102 to output positive polarity welding-type power while the other socket connector 500 is used in theelectrical panel 102 to output negative polarity welding-type power. In some examples, two of the same socket connectors 500 may be used to output both positive and negative polarity welding-type power. In some examples, one of the socket connector 500 may be used in theelectrical panel 102 and configured to output positive or negative polarity welding-type power, while a different socket connector (not shown) may be used in theelectrical panel 102 and configured to output the other polarity of welding-type power. In some examples, theoperator interface 28 may include a control element that allows for selection of power socket polarity. - In the examples of
FIGS. 5 a-5 d , each socket connector 500 comprises an inner surface and an outer surface. The outer surface includes acollar 502, abody 504 that extends from thecollar 502, and anose 506 that extends from thebody 504. In the examples ofFIGS. 3 a-5 d , thecollar 502 is generally circular, with two opposing and/orparallel wrench flats 508. Thecollar 502 has a shape similar to that of theslot 406, so as to provide a snug fit within theslot 406. Thecollar 502 may be configured to abut theshoulder 410 and/or taper 412 of thebulkhead 400 when assembled within theslot 406. - In the examples of
FIGS. 5 a-5 d , thebody 504 of each socket connector 500 is generally cylindrical, and includes agroove 510 in an approximate middle of thebody 504 configured to fit an O-ring. In the example ofFIGS. 5 b and 5 d , thecollar 502 has the largest outer diameter, followed by thebody 504, then thenose 506, and then thegroove 510. When thepower socket 300 is fully assembled, thebody 504 may be substantially and/or entirely covered bybulkhead 400 and/orcap 302. However, thenose 506 extends forward from thebody 504, such that thenose 506 extends further into thehousing 104, beyond thecap 302, therefore remaining uncovered within thehousing 104. - In the examples of
FIGS. 5 a-5 d , thenose 506 includes engagement features, such as screw threads, for example. The engagement features of thenose 506 may be configured to engage with complementary engagement features (e.g., threaded grooves) of anut 306. As may be seen inFIGS. 3 a and 3 c , for example, thenut 306 may be combined with awasher 308 to retain the socket connector 500 within the slot 406 (in conjunction with theshoulder 410 and/or taper 412) and to retain thecap 302 over thebulkhead 400 and/orbody 504 of the socket connector 500. - In the examples of
FIGS. 5 a-5 d , the inner surface of each socket connector 500 surrounds abore 512 that extends through the socket connector 500. The inner surface of the socket connector includes acontact surface 514, acoupling surface 518, and acentral surface 516. In the examples ofFIGS. 5 b and 5 d , thecontact surface 514 extends from thecollar 502 into thebody 504, and terminates short of thegroove 510. Thecentral surface 516 extends from thecontact surface 514 towards thenose 506. Thecoupling surface 518 extends from thecentral surface 516 towards a receiving surface 520, further explained below. As shown, the diameter of thebore 512 is largest at the contact surface and smallest at thecoupling surface 518, with thebore 512 having a diameter at thecentral surface 516 that is larger than the diameter of thebore 512 at thecoupling surface 518, but smaller than the diameter of thebore 512 at thecontact surface 514. - The
contact surface 514 is configured to make electrical contact with anose 614 of an insert 600. In the examples ofFIGS. 5 b and 5 d , thecontact surface 514 is approximately conical (and/or frustoconical), such that thebore 512 decreases in diameter traveling from thecollar 502 in towards thecentral surface 516. The conical (and/or frustoconical) shape of thecontact surface 514 provides a substantial surface area for electrical contact, and increases the likelihood of good electrical contact when an insert 600 is firmly secured to the socket connector 500. - In the examples of
FIGS. 5 b and 5 d , thecentral surface 516 lies between thecontact surface 514 and thecoupling surface 518. Thecentral surface 516 encircles a portion of thebore 512 that is configured to fit anut 616 of the insert 600. Thecoupling surface 518 is configured to engage acomplementary coupler 618 of the insert 600. Thecoupling surface 518 may include engagement features, such as, for example, threaded grooves, to connect with (and/or attach to) complementary engagement features of acoupler 618 of the insert 600. - In the example of
FIG. 5 b , the inner surface of thesocket connector 500 a further includes a receivingsurface 520 a that is configured to receive and make contact with one or more electrical conductors (and/or wires, wiring, cables, leads, clips etc.) coming from thepower conversion circuitry 32. In some examples, the electrical conductors may extend into thebore 512 encircled by the receivingsurface 520 a so as to connect the socket connector 500 to thepower conversion circuitry 32. In some examples, the socket connector 500 may additionally, or alternatively, be connected to thepower conversion circuitry 32 via thenose 506, which may make electrical contact with one or more electrical conductors. In the example ofFIG. 5 d , thesocket connector 500 b has adifferent receiving surface 520 b that is part of the outer surface of thesocket connector 500 b. The receivingsurface 520 b extends from thenose 506, and has ahole 522 that may receive a bolt or other fastener so as to couple the one or more electrical conductors to thesocket connector 500 b. - Each socket connector 500 is configured for coupling to a plurality of inserts 600. In the example of
FIG. 3 a , three inserts 600 are shown. Any of the inserts 600 may be coupled to either socket connector 500. In some examples, other inserts (not shown) may be coupled to the socket connectors 500. Each insert 600 may be comprised of an electrically conductive material, such as brass, copper, and/or any other appropriately conductive material. As shown, each insert 600 has a “male” end with acoupler 618 for connecting to the socket connector 500, and a “female” end with a keyed entryway 602 for connecting to a key interface 802 of aplug 700, as discussed further below. In some examples, an insert 600 may instead include two “male” ends. However, having one end be a “male” end and the other end be a “female” end configured for connecting to theplug 700 advantageously avoids additional and/or unnecessary outcroppings on the welding-type power supply 12 and/orpower supply housing 104. - Each “female” end keyed entryway 602 is configured to accept (and/or receive, connect with, attach to, engage with, etc.) a particular type of
plug 700 that has a particular complementary (and/or matching) key interface 802. Thecoupler 618 of each insert 600 has engagement features configured for secure external connection to the complementary engagement features of thecoupling surface 518 of the socket connector 500. Thus, an operator may securely and externally reconfigure apower socket 300 of a welding-type power supply 12 for a different type ofplug 700, without having to access the internals of thehousing 104, and without worrying that the insert 600 will become mechanically and/or electrically removed from thepower socket 300 if/when the operator removes theplug 700 from thepower socket 300. - In the examples of
FIGS. 3 a and 6 a-6 f , each insert 600 includesbody 604 and acoupler 618. The body includes abase 606 and anose 614. As shown, thebase 606 has an outer surface that is approximately cylindrical, with parallel and opposingflats 608 that truncate the cylinder. The shape of thebase 606 approximates that of theslot 406 of thebulkhead 400, so that the insert 600 may fit within thebulkhead 400 to connect with the socket connector 500. As shown, thenose 614 extends from thebase 606. In the examples ofFIGS. 3 a and 6 a-6 f , thenose 614 is approximately conical (and/or frustoconical), being shaped (and/or configured) to electrically contact (and/or connect) with thecontact surface 514 of the socket connector 500. - In the examples of
FIGS. 3 a and 6 a-6 f , each insert 600 includes acoupler 618 comprising ashoulder screw 610 and anut 616 engaged to theshoulder screw 610. As shown, theshoulder screw 610 includes ahead 620 attached to ashank 622. Theshank 622 extends between thehead 620 and ascrew thread 624. Thehead 620 is positioned within arecess 626 of thenose 614, and includes atool interface 628 configured to receive a work end of a tool, such as a screwdriver and/or Allen wrench, for example. When assembling and/or disassembling the insert 600 into and/or out of thepower socket 300, an operator may insert a tool end of a tool into thetool interface 628 and turn theshoulder screw 610 via the tool andtool interface 628 connection, so as to couple and/or uncouple thescrew threads 624 from thecoupling surface 518 of the socket connector 500. - In the examples of
FIGS. 3 a and 6 a-6 f , thescrew threads 624 extend out of thenose 614 of the insert 600, along with a small sliver of theshank 622. As shown, thenut 616 is engaged to thescrew threads 624 adjacent to thenose 614. As theshoulder screw 610 is not integrally connected to the rest of the insert 600 in the examples ofFIGS. 3 a and 6 a-6 f , thenut 616 ensures thatbody 604 is removed along with theshoulder screw 610 when removing the insert 600 from the socket connector 500. For instance, during operation, thepower socket 300 may undergo heating due to thermal effects of the electrical power conducted through thepower socket 300. Thepower socket 300 may eventually cool down when the welding-type system 10 and/or welding-type power supply 12 is no longer in use. The repeated heating and cooling may cause thenose 614 of the insert 600 to partly fuse with thecontact surface 514 of the socket connector 500. Thus, without thenut 616, an operator may attempt to remove the insert 600 via thetool interface 628 of theshoulder screw 610, and only succeed in removing theshoulder screw 610 from thebody 604 of the insert 600, while the nose 614 (and/or body 604) of the insert 600 remains fused to thecontact surface 514. However, with thenut 616 in place, theshoulder screw 610 is prohibited from being removed from thebody 604 of the insert 600. Instead, the mechanical force that would have removed theshoulder screw 610 from thebody 604 of the insert 600 is instead applied to thenut 616, and in turn applied by thenut 616 to thenose 614. This mechanical force may help to dislodge a fusednose 614 andcontact surface 514, and allow the insert 600 to be successfully removed from the socket connector 500. - As shown in the examples of
FIGS. 3 a and 6 a-6 f , thebase 606 of each insert 600 includes a keyed entryway 602. Each keyed entryway 602 is configured to receive a particular key interface 802 of aplug 700, as further discussed below. Thekeyed entryway 602 a of theinsert 600 a is different from thekeyed entryway 602 b of theinsert 600 b, such that aplug 700 intended forinsert 600 b will not work withinsert 600 a, and vice versa. In particular, theinsert 600 a is configured to work with DINSE-type plugs 700, while theinsert 600 b is configured to work with TWECO-type plugs 700. More particularly, each keyed entryway 602 comprises a hollow opening within the interior of thebase 606, with a keyed surface that uniquely configures the opening for a particular type ofplug 700. - As may be seen, for example, in
FIGS. 3 a, 6 a, and 6 b , theinsert 600 a includes akeyed entryway 602 a. As shown, thekeyed entryway 602 a is shorter and less wide (with a smaller diameter) than thekeyed entryway 602 b inFIG. 6 d . As shown, thekeyed entryway 602 a includes agroove 629 in the inner surface of thebase 606. Thegroove 629 comprises the keyed surface of thekeyed entryway 602 a. Thegroove 629 expands thekeyed entryway 602 a within thebase 606 along the axial length of thekeyed entryway 602 a. Thegroove 629 expands thekeyed entryway 602 a, so as to increase the diameter of thekeyed entryway 602 a along its axial length. As shown inFIGS. 6 a and 6 b , thegroove 629 becomes slightly shallower at aninflection point 632. The keyed entryway 602 also includes asecond groove 634 that expands the diameter of the keyed entryway in an arc around the keyed entryway at theinflection point 632. Thesecond groove 634 provides space for aridge 822 of acorresponding plug 700 to rotate within thekeyed entryway 602 a at theinflection point 632. Thus, the width of thesecond groove 634 may be approximately equal to (or slightly larger than) a width (and/or thickness) of theridge 822. The configuration of thekeyed entryway 602 a comprises a DINSE-type (and/or style) configuration. - In operation, a DINSE-
type plug 700 would have akey interface 802 a comprising acylindrical stem 820 with theridge 822, such that thestem 820 could be inserted into thekeyed entryway 602 a when theridge 822 is in alignment with thegroove 629. Thereafter, the plug 700 (and/or stem 820) could be turned and/or twisted within thekeyed entryway 602 a to move theridge 822 out of alignment with thegroove 629, thereby securing theplug 700 within thekeyed entryway 602 a. When thus secured, the interior surface of thebase 606 provides an electrical connection with thekey interface 802 a of theplug 700. Thegroove 629 prevents anynon-DINSE plug 700 from connecting with theinsert 600 a. - As may be seen, for example, in
FIGS. 6 c and 6 d , theinsert 600 b includes akeyed entryway 602 b with a keyed surface comprising alatch 630 that protrudes into thekeyed entryway 602 b. As shown, thelatch 630 is a protuberance that extends from an inner surface of thebase 606 of theinsert 600 b into the opening of thekeyed entryway 602 b. In the examples ofFIGS. 6 c and 6 d , thelatch 630 lessens the diameter of thekeyed entryway 602 b within thebase 606. Notably, the keyed entryway 602 has an approximately consistent diameter most everywhere else within thebody 604 of theinsert 600 b. Thelatch 630 is positioned closer to thenose 614 of theinsert 600 b than the beginning of thekeyed entryway 602 b. The configuration of thekeyed entryway 602 b comprises a TWECO-type (and/or style) configuration. - In operation, a TWECO-
type plug 700 would have akey interface 802 b comprising acylindrical stem 820 with acutout 823 that matched thelatch 630, such that thestem 820 could be inserted into thekeyed entryway 602 b at an orientation where thecutout 823 aligned with thelatch 630, so that thestem 820 could pass by thelatch 630. Thereafter, the plug 700 (and/or stem 820) could be turned and/or twisted within thekeyed entryway 602 b to move thecutout 823 out of alignment with thelatch 630, thereby securing theplug 700 within thekeyed entryway 602 b. When thus secured, the interior surface of thebase 606 provides an electrical connection with thekey interface 802 b of theplug 700. Thelatch 630 prevents any non-TWECO-plug 700 from connecting with theinsert 600 b. - As may be seen, for example, in
FIGS. 6 e and 6 f , theinsert 600 c includes akeyed entryway 602 c with a keyed surface comprising a pair of opposing grooves. Each of thegrooves 652 has aninflection point 654, similar to thegroove 629 andinflection point 632 of theinsert 600 a. Thekeyed entryway 602 c (and/or keyed surface) further includes threadedgrooves 650 to assist with turning of acomplementary plug adapter 800 c. In operation, shoulders 827 of acomplementary plug adapter 800 c may move within thegrooves 652, until encountering theinflection points 654, at which point theplug adapter 800 c may be turned to take theshoulders 827 out of alignment with thegrooves 652. In some examples, one or more of theinflection points 654 may be omitted from theinsert 600 c. - In some examples, the
plug adapter 800 c may have a key interface 802 similar to the stem portion described in U.S. Pat. No. 7,377,825, which is owned by the assignee of the present application, and hereby incorporated by reference. In some examples, theinsert 600 c may have a base 606 similar to portions of the receptacle U.S. Pat. No. 7,377,825. -
FIGS. 7 a and 7 b show examples of welding-typepower plug assemblies plug assembly 700 inFIG. 7 a may be considered a “male”plug assembly 700, while theplug assembly 701 inFIG. 7 b may be considered a “female”plug assembly 701. As shown, theplug assembly 700 includes a plug adapter 800, aplug receptacle 900, and aplug cover 702. Theplug assembly 701 includes a plug adapter 801, aplug receptacle 900, and aplug cover 702. The plug adapters 800, 801 and plugreceptacle 900 may be comprised of electrically conductive material, such as brass and/or copper, for example. Theplug cover 702 may be comprised of an electrically and/or thermally insulating material (e.g., rubber), so as to allow an operator to grasp theplug assembly 700 during operation. In the examples ofFIGS. 10 b and 10 c , theplug cover 702 encloses theplug receptacle 900 and much of the plug adapter 800, 801 when theplug assembly 700 is assembled together. In some examples (e.g.,FIG. 10 b ), portions of the plug adapter 800, 801 may extend beyond theplug cover 702 when theplug assembly FIG. 10 c ), theplug cover 702 may encircle the entirety of the plug adapter 800, 801 when theplug assembly -
FIGS. 7 a, 7 b, 9 a, and 9 b show anexample receptacle 900. As shown, thereceptacle 900 includes an outer surface and an inner surface. The outer surface includes abase 902 and atube 904. In the examples ofFIGS. 7, 9 a, and 9 b, both thebase 902 andtube 904 are approximately cylindrical. As shown, thebase 902 has opposingwrench flats 908 that truncate the cylindrical shape of the base. Thebase 902 includes cap screw holes 910 on opposing sides of thebase 902. Thetube 904 includes axially aligned set screw holes 912. The surfaces encircling the set screw holes 912 and/or cap screw holes 910 may be formed with threaded grooves to engage the screws. - The inner surface of the
receptacle 900 encircles aconduit 914 that extends through thereceptacle 900. The inner surface includes anadapter interface 916, atail interface 918 and acable interface 920. As shown, the diameter of theconduit 914 is largest at the beginning of theadapter interface 916, then narrows to a smaller diameter within thetail interface 918, before expanding again within thecable interface 920. Theadapter interface 916 is shaped approximately conically (and/or frustoconically) and is configured to contact, connect, and/or interface with thereceptacle interface 806 of the plug adapter 800, so as to establish an electrical connection between the plug adapter 800 and thereceptacle 900. The diameter of theconduit 914 at the widest point within theadapter interface 916 is smaller than the diameter of acentral disc 804 of the plug adapter 800 (and/orbody 604 of the plug adapter 801), such that thecentral disc 804 will not fit within theconduit 914. - In the example of
FIGS. 7 a, 7 b, and 9 b , theplug receptacle 900 includes opposing cap screw holes 910 in the outer surface that lead to thetail interface 918. As shown, thetail interface 918 is approximately cylindrical. In some examples, thetail interface 918 may be formed with engagement features, such as threaded grooves, for example, to engage complementary engagement features on thetail 818. When theplug assembly plug cover 702 to receivecap screws 710, such as nylon cap screws, for example. In some examples, the cap screws 710 may be formed of some other electrically and/or thermally insulating material. The surface of thereceptacle 900 surrounding the cap screw holes 910 may include threaded grooves to receive the cap screws 710. In operation, the cap screws 710 may assist in frictionally retaining thetail 818 within theconduit 914 encircled by thetail interface 918. - In the examples of
FIGS. 7 a, 7 b, and 9 b , theplug receptacle 900 further includes set screw holes 912 that lead to thecable interface 920. As shown, thecable interface 920 is approximately cylindrical. The set screw holes 912 may be encircled by threaded grooves, to receive setscrews 712. Theset screws 712 may be formed of electrically conductive material, such as a metallic material, for example. When theplug assembly 700 is assembled together with awelding cable 1000, exposedwiring 1002 of the welding cable 1000 (that has been stripped of insulation 1004) may be held against thecable interface 920 byset screws 712 within the set screw holes 912 to provide an electrical connection between thewelding cable 1000 and theplug receptacle 900. - In the examples of
FIGS. 7 a and 7 b , several different plug adapters 800, 801 are shown. InFIG. 7 a , plug adapters 800 a-800 c include “male” style key interfaces 802. InFIG. 7 b , the plug adapters 801 a-801 c include “female” style key entryways 602, similar to the key entryways 602 of the socket inserts 600.FIG. 10 b shows an example assembledplug assembly 700 with theplug adapter 800 a.FIG. 10 c shows an example assembledplug assembly 701 with theplug adapter 801 a. It should be understood that any of the plug adapters 800, 801 could be interchanged with theplug adapters FIGS. 10 b and 10 c , and/or otherwise used with thesocket assembly 700. - In the examples of
FIGS. 7 a and 8 a-8 i , the plug adapters 800 include acentral disc 804 havingwrench flats 808 that may be used by a wrench (and/or other appropriate tool) to connect and/or disconnect the plug adapter 800 to/from theplug receptacle 900. The plug adapter 800 further includes a key interface 802, areceptacle interface 806, and atail 818. The key interface 802 andreceptacle interface 806 extend from opposite faces of thecentral disc 804. In the examples ofFIG. 7 , thereceptacle interface 806 is a conical (and/or frustoconical) surface. Thereceptacle interface 806 is configured to electrically contact, connect to, and/or interface with a complementary surface in theplug receptacle 900, so as to establish an electrical connection with theplug receptacle 900, through which electrical power may flow. - In the examples of
FIGS. 7 a and 8 a-8 i , thereceptacle interface 806 and thetail 818 connect at an end opposite of the key interface 802. As shown, thetail 818 is approximately cylindrical, with an outer diameter slightly less than thestem 820 of the key interface 802. Thetail 818 may be formed with engagement features, such as screw threads, for example. Thetail 818 may be configured to engage with thetail interface 918 of thereceptacle 900, such as through complementary engagement features (e.g., threaded grooves) of thetail interface 918. Thus, thetail 818 and tail interface 918 (with or without with cap screws 710) may allow an operator to securely connect the plug adapter 800 to, and disconnect the plug adapter from, thereceptacle 900, as desired. - In the example of
FIGS. 8 a-8 c , thekey interface 802 a of theplug adapter 802 a comprises acylindrical stem 820 with a key interface feature. As shown, the key interface feature comprises aridge 822 that protrudes radially away from the body. As shown, theridge 822 is sized, shaped, and/or otherwise configured to fit through thegroove 629 of thekeyed entryway 602 a. Thus, theplug assembly 700 may be connected with thesocket 300 by inserting the key interface 802 into thekeyed entryway 602 a of the insert 600, whereby theridge 822 will move through thegroove 629 until theridge 822 hits theinflection point 632. Thereafter, theplug assembly 700 may be turned and/or twisted to move theridge 822 through thesecond groove 634, to a point where theridge 822 is out of alignment with the groove 632 a. Once theridge 822 is out of alignment with the groove 632 a, theplug assembly 700 may not be removed from thesocket 300 without moving theridge 822 back into alignment. -
FIGS. 8 d-8 i showexample plug adapters FIGS. 8 d-8 f , theplug adapter 800 b includes akey interface 802 b with a key interface feature comprising acutout 823 in thestem 820 of the key interface 802. Thecutout 823 results in aflat surface 824 that extends from anend 826 of thekey interface 802 b to asemicircular wall 829. Thecutout 823 further forms anannular channel 830 that circles part of theflat surface 826, forming ahook 832. In operation, thecutout 823 is configured to allow the key interface 802 to proceed past thelatch 630 in thekeyed entryway 602 b. Theannular channel 830 provides a path for thelatch 630 when the key interface 802 rotates within the keyed entryway 602. After rotation, thecutout 823 will be out of alignment with thelatch 630, and thehook 832 will grasp thelatch 630, so that the key interface 802 may not be withdrawn from the keyed entryway 602. - In the example of
FIGS. 8 g-8 i , theplug adapter 800 c includes akey interface 802 c with astem 820 that is not completely cylindrical. Rather, thestem 820 includesflat sides 828 that truncate the otherwisecylindrical stem 820. The cylindrical portions of thestem 820 are formed withscrew threads 834. Extending from thestem 820 is a key interface feature comprising a pair of opposingshoulders 827 formed on opposite sides of the cylindrical portions of thestem 820. Theshoulders 827 are configured to pass through a pair of opposinggrooves 652 in akeyed entryway 602 c of theinsert 600 c (and/or plugadapter 801 c). In some examples, the plug adapter 800 may have a key interface 802 similar to the stem portion described in U.S. Pat. No. 7,377,825, which is owned by the assignee of the present application, and hereby incorporated by reference. -
FIGS. 7 b and 8 j-8 r show plug adapters 801 that have a “female” keyed entryway 602, similar to the keyed entryways 602 of the socket inserts 600. The plug adapters 801 share features with both the socket inserts 600 and the plug adapters 800. In the examples ofFIGS. 7 b, 8 j-8 r, and 10 c , the plug adapters 801 still have thetail 818 and receptacle interface 806 (and/or nose 614), but nocentral disc 804 or key interface 802. Instead, the plug adapter 800 has abody 604 comprising of a base 606 with a keyed entryway 602, similar to that of the inserts 600. As all of these features were previously described, they will not be enumerated again here. -
FIG. 11 shows anexample method 1100 for configuring and/or reconfiguring a welding-type power socket 300 and/or plugassembly 700 for welding-type operation. While the disclosure refers to an operator, it should be understood that, in some examples, an automated machine, such as a robot for example, may take the role of an operator. Themethod 1100 begins atblock 1102, assuming that theplug assembly 700 is disconnected from thepower socket 300, and the one or more socket connectors 500 are firmly attached within thebulkheads 400 of theelectrical panel 102 of the welding-type power supply 12. Atblock 1104, the operator may attach one of the inserts 600 to the socket connector 500, if desired, such as by securely coupling thecoupler 618 of the insert 600 to thecoupling surface 518 of the socket connector 500. At block 1106, the operator may attach one of the plug adapters 800, 801 to theplug receptacle 900, such as by connecting thetail 818 of the plug adapter 800 to thetail interface 918 of theplug receptacle 900, and further tightening the cap screws 710. Presumably the operator will attach an insert 600 with a keyed entryway 602 that corresponds to the key interface 802 of the plug adapter 800 being attached to theplug receptacle 900. In some examples, blocks 1104 and/or 1106 may be skipped if the correct and/or desired socket insert(s) 600 and/or plug adapter(s) 800 are already attached. At block 1108, theplug assembly 700 is connected to thepower socket 300 by inserting the key interface 802 into the keyed entryway 602 and twisting and/or turning the plug assembly, so as to move the key interface 802 into a locking arrangement with the keyed entryway 602, with the key interface feature out of alignment with the keyed surface. - At
block 1110 the operator may determine whether a good connection has been made. If not, themethod 1100 proceeds to block 1112, discussed further below. If so, the method proceeds to block 1114, where a welding operation may take place, using the welding-type power flowing from the welding-type power supply 12, through the connection between the welding-type power socket 300 and theplug assembly 700 and to the appropriate welding component. In some examples, thewelding cable 1000 may lead to anotherplug assembly 700 having a “female” plug adapter 800, which may in turn be attached to anotherplug assembly 700 having a “male” plug adapter 800, and so on in a daisy chain and/or extension fashion until thewelding cable 1000 terminates in a welding component. - At
block 1116, the operator may determine whether the welding type operation is finished. If not, block 1114 continues and/or repeats. If so, themethod 1100 proceeds to block 1112, where the operator may disconnect theplug assembly 700 from thepower socket 300. In some examples, this block may be skipped if further welding-type operations are planned for the near future. Themethod 1100 then proceeds to block 1118, where the operator may remove the insert 600 and/or plug adapter 800 from thepower socket 300 and/or plugassembly 700, if so desired. In some examples, thisblock 1118 may be skipped if, for example, further welding-type operations are planned in the near future using the currently attached insert 600 and/or plug adapter 800. The method once again ends/begins atblock 1102. - While the present apparatuses, systems, and/or methods have been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present apparatuses, systems, and/or methods. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present apparatuses, systems, and/or methods not be limited to the particular implementations disclosed, but that the present apparatuses, systems, and/or methods will include all implementations falling within the scope of the appended claims.
Claims (20)
1. A removable insert for a socket of a welding power supply, comprising:
a base having a keyed entryway configured to connect with a key interface of a plug, the keyed entryway comprising a bore encircled by an inner surface of the base, the inner surface having a fixed keyed surface comprising a TWECO style latch that protrudes into the bore or a DINSE style axial groove that expands the bore;
a nose comprising a contact surface configured to make electrical contact with a complementary contact surface of a socket connector of the welding power supply, thereby enabling conduction of electricity from the welding power supply to the plug; and
a coupler configured to couple the removable insert to the socket connector, thereby ensuring good electrical contact and connection with the socket connector of the welding power supply.
2. The removable insert of claim 1 , wherein the bore of the keyed entryway leads to the coupler, the coupler comprising a shoulder screw.
3. The removable insert of claim 2 , wherein the bore of the keyed entryway leads to a recess in the nose, at least a portion of the coupler being retained in the recess.
4. The removable insert of claim 1 , wherein the contact surface comprises a frustoconical surface.
5. The removable insert of claim 1 , wherein the coupler comprises a shoulder screw, the shoulder screw having a head at a first end of the shoulder screw, a screw thread at a second end that is opposite the first end, and a shank connecting the head to the screw thread, the screw thread being configured to engage complementary threaded grooves of the socket connector.
6. The removable insert of claim 4 , wherein the head of the shoulder screw is positioned within a recess of the nose, the head having a tool interface configured for coupling to a tool.
7. The removable insert of claim 4 , wherein the coupler further comprises a nut screwed to the screw thread.
8. A removable insert for a socket of a welding power supply, comprising:
a base having a keyed entryway configured to connect with a key interface of a plug, the keyed entryway comprising a bore encircled by an inner surface of the base, the inner surface having a fixed keyed surface comprising a TWECO style latch that protrudes into the bore;
a nose comprising a contact surface configured to make electrical contact with a complementary contact surface of a socket connector of the welding power supply, thereby enabling conduction of electricity from the welding power supply to the plug; and
a coupler configured to couple the removable insert to the socket connector, thereby ensuring good electrical contact and connection with the socket connector of the welding power supply.
9. The removable insert of claim 8 , wherein the bore of the keyed entryway leads to the coupler, the coupler comprising a shoulder screw.
10. The removable insert of claim 9 , wherein the bore of the keyed entryway leads to a recess in the nose, at least a portion of the coupler being retained in the recess.
11. The removable insert of claim 8 , wherein the contact surface comprises a frustoconical surface.
12. The removable insert of claim 8 , wherein the coupler comprises a shoulder screw, the shoulder screw having a head at a first end of the shoulder screw, a screw thread at a second end that is opposite the first end, and a shank connecting the head to the screw thread, the screw thread being configured to engage complementary threaded grooves of the socket connector.
13. The removable insert of claim 12 , wherein the head of the shoulder screw is positioned within a recess of the nose, the head having a tool interface configured for coupling to a tool.
14. The removable insert of claim 12 , wherein the coupler further comprises a nut screwed to the screw thread.
15. A removable insert for a socket of a welding power supply, comprising:
a base having a keyed entryway configured to connect with a key interface of a plug, the keyed entryway comprising a bore encircled by an inner surface of the base, the inner surface having a fixed keyed surface comprising a DINSE style axial groove that expands the bore;
a nose comprising a contact surface configured to make electrical contact with a complementary contact surface of a socket connector of the welding power supply, thereby enabling conduction of electricity from the welding power supply to the plug; and
a coupler configured to couple the removable insert to the socket connector, thereby ensuring good electrical contact and connection with the socket connector of the welding power supply.
16. The removable insert of claim 15 , wherein the bore of the keyed entryway leads to the coupler, the coupler comprising a shoulder screw.
17. The removable insert of claim 16 , wherein the bore of the keyed entryway leads to a recess in the nose, at least a portion of the coupler being retained in the recess.
18. The removable insert of claim 15 , wherein the contact surface comprises a frustoconical surface.
19. The removable insert of claim 15 , wherein the coupler comprises a shoulder screw, the shoulder screw having a head at a first end of the shoulder screw, a screw thread at a second end that is opposite the first end, and a shank connecting the head to the screw thread, the screw thread being configured to engage complementary threaded grooves of the socket connector, and the coupler further comprising a nut screwed to the screw thread.
20. The removable insert of claim 19 , wherein the head of the shoulder screw is positioned within a recess of the nose, the head having a tool interface configured for coupling to a tool.
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US18/418,701 US20240162671A1 (en) | 2018-07-12 | 2024-01-22 | Reconfigurable welding-type power sockets and power plugs |
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US16/033,922 US11894642B2 (en) | 2018-07-12 | 2018-07-12 | Reconfigurable welding-type power sockets and power plugs |
US18/418,701 US20240162671A1 (en) | 2018-07-12 | 2024-01-22 | Reconfigurable welding-type power sockets and power plugs |
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US18/418,701 Pending US20240162671A1 (en) | 2018-07-12 | 2024-01-22 | Reconfigurable welding-type power sockets and power plugs |
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-
2018
- 2018-07-12 US US16/033,922 patent/US11894642B2/en active Active
-
2019
- 2019-06-14 WO PCT/US2019/037271 patent/WO2020013953A1/en unknown
- 2019-06-14 MX MX2021000335A patent/MX2021000335A/en unknown
- 2019-06-14 EP EP19734643.0A patent/EP3820642B1/en active Active
- 2019-06-14 CA CA3105631A patent/CA3105631C/en active Active
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2024
- 2024-01-22 US US18/418,701 patent/US20240162671A1/en active Pending
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EP3820642B1 (en) | 2023-08-02 |
WO2020013953A1 (en) | 2020-01-16 |
US20200021070A1 (en) | 2020-01-16 |
MX2021000335A (en) | 2021-03-25 |
EP3820642A1 (en) | 2021-05-19 |
US11894642B2 (en) | 2024-02-06 |
CA3105631A1 (en) | 2020-01-16 |
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